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Article history:
Accepted 5 October 2008
Keywords:
High speed machining
Ti6Al4V
Inconel 718
Cutting forces
Round cutting edge tool
a b s t r a c t
Titanium alloy Ti6Al4V and nickel-based superalloy Inconel 718 have been widely employed in modern manufacturing. The published literature on high speed machining (HSM) of the two materials often
involves different machining set-up, which makes it difcult to directly apply the research ndings from
one material to the other to select the most appropriate tool geometry and cutting conditions. A comparative experimental study of HSM of Ti6Al4V and Inconel 718 is conducted in this paper using the same
machining set-up. The scope of this study is limited in high speed nish machining, where the tool edge
geometry plays a signicant role. The experimental set-up and the methods of measuring the cutting
forces and the tool edge radius are introduced. A total of 40 orthogonal high speed tube-cutting tests
were performed, involving ve levels of cutting speeds and four levels of feed rates. Based on extensive
experimental data, the similarities and differences between HSM of Ti6Al4V and Inconel 718 are quantitatively compared and qualitatively explained in terms of four quantities: (1) the cutting force Fc , (2)
the thrust force Ft , (3) the resultant force R, and (4) the force ratio Fc /Ft . A total of 12 empirical regression
relationships are obtained.
2008 Elsevier B.V. All rights reserved.
1. Introduction
Among the most effective and efcient modern manufacturing
technologies, high speed machining (HSM) is employed to increase
productivity while simultaneously improving product quality and
reducing manufacturing costs. Depending on work and tool materials as well as tool life requirements, the cutting speed used in
HSM is often 250 times higher than those employed in traditional
(relatively low speed) machining. Due to its high material removal
rate and short product cycle time, HSM has received steadily growing applications in recent years in many industrial sectors, such
as defense, aerospace, aircraft, automotive, and die- and mouldmaking.
Research on HSM involves a wide variety of work materials ranging from easy-to-cut aluminum alloys (Schulz et al., 2001; Siems
et al., 2000) to difcult-to-cut hardened steels (Quan et al., 2004;
Behrens et al., 2004) and advanced aerospace materials (Ezugwu
and Bonney, 2003). Among advanced aerospace materials, two have
been extensively studied: titanium alloy Ti6Al4V (Su et al., 2006;
Molinari et al., 2002; Baker et al., 2002; Komanduri and Hou, 2002;
Barry et al., 2001; Bayoumi and Xie, 1995) and nickel-based superalloy Inconel 718 (Nalbant et al., 2007; Ezugwu et al., 2005; Dudzinski
and Devillez, 2004; Coelho et al., 2004; Narutaki and Yamane, 1993).
Due to their exceptionally high strength-to-weight ratio, excellent
mechanical properties (especially high temperature performance),
and superior corrosion resistance, Ti6Al4V and Inconel 718 have
received growing applications in making critical parts, components,
and structures. For example, titanium alloy components make up
2030% of the dry weight in a jet engine. However, because of
their high strength and low thermal conductivity (Nabhani, 2001;
Arunachalam and Mannan, 2000), HSM of these two materials often
cause numerous problems in modern manufacturing.
The published literature undoubtedly advances the fundamental
understanding of various aspects of HSM processes. However, little literature is available to compare HSM of Ti6Al4V and Inconel
718 while keeping all the other machining set-up (such as the cutting conditions, tool geometry, and tool material) the same. The vast
majority of the published literature focuses on either Ti6Al4V (Su
et al., 2006; Molinari et al., 2002; Baker et al., 2002; Komanduri and
Hou, 2002; Barry et al., 2001; Bayoumi and Xie, 1995) or Inconel 718
(Nalbant et al., 2007; Ezugwu et al., 2005; Dudzinski and Devillez,
2004; Coelho et al., 2004; Narutaki and Yamane, 1993) alone, often
involving different machining set-up. The research ndings from
HSM of one material might not be directly applicable to HSM of the
other material. A comparative study that uses the same machining set-up not only improves the scientic understanding of the
effect of different aerospace materials in HSM, but also makes it
feasible to extend the research ndings from one material to the
4386
Table 2
Chemical composition (%) of Ti6Al4V.
Element
C
Al
Fe
V
Ti
%
<0.08
5.56.75
<0.4
3.54.5
Element
V
N
H
O
3.54.5
<0.05
<0.01
<0.2
Balance
Table 3
Chemical composition (%) of Inconel 718.
Element
C
Ni
Cr
Nb
Mo
Ti
%
0.08
5055
1721
4.755.5
2.83.3
0.651.15
Element
Co
Al
Si
Mn
Cu
Fe
Tool insert
Tool material
Tool working rake angle
Tool edge radius
Cutting speed
Feed rate
Value
Ti6Al4V and Inconel 718
50 mm
1.4 mm for Ti6Al4V
1.2 mm for Inconel 718
TPG 432 (Kennametal Inc.)
Cemented carbide (KC 8050) with TiC/TiN/TiCN
coating
5
0.06 mm
58, 87, 116, 144, 174 m/min
0.075, 0.09, 0.105, 0.12 mm/r
%
1.0
0.20.8
0.35
0.35
0.3
Balance
edge radius (0.06 mm) were used. All feed rates were at least 10
times smaller than the width of cut (i.e., the wall thickness of the
workpiece tube) to ensure plane-strain deformation conditions in
orthogonal cutting.
Tables 2 and 3 show the chemical compositions of the two work
materials tested in this study. As seen, Inconel 718 contains a signicant amount of Ni and Cr.
Table 1
Experimental set-up.
Category
4387
Fig. 3. The thrust force vs. the cutting conditions: (a) Ti6Al4V and (b) Inconel 718.
4388
Ti64
In718
= 10
3.41
Vc
0.216 0.495
(3)
(4)
3.80
Vc
0.175 0.746
(5)
(6)
= 10
0.394
Vc
0.0635 0.400
(7)
(8)
Fig. 4. The resultant force vs. the cutting conditions: (a) Ti6Al4V and (b) Inconel
718.
Fc
Ti64
Fc
In718
(1)
(2)
Fig. 5. The force ratio vs. the cutting conditions: (a) Ti6Al4V and (b) Inconel 718.
4389
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Fc
Ft
RIn718 /RTi64 = 10
Fc In718 /Ft
Fc Ti64 /Ft
In718
Ti64
0.39
0.36
Vc
Vc
0.041 0.368
0.027 0.0263
(9)
(10)
(11)
(12)
Eqs. (9)(12) reveal that the cutting forces and the force ratio are
governed not only by work materials, but also by the interactions
among work materials, the cutting speed, and the feed rate.
5. Conclusions
A comparative experimental study of high speed machining of
two major aerospace materials titanium alloy Ti6Al4V and
Inconel 718 has been performed. Based on extensive experimental data generated from 40 orthogonal high speed tube-cutting
tests that involved ve levels of cutting speeds and four levels of feed rates for each work material, the similarities and
differences in machining the two materials are summarized as
follows:
(1) For both materials: as the cutting speed increases, the cutting
force, the thrust force, and the result force all decrease; however,
the force ratio increases.
(2) For both materials: as the feed rate increases, the cutting force,
the thrust force, the result force, as well as the force ratio all
increase.
(3) Under the same cutting conditions, the cutting force and the
thrust force in machining Inconel 718 are higher than those in
machining Ti6Al4V.
(4) The variation of the thrust force with the feed rate is smaller
in machining Ti6Al4V than that in machining Inconel 718,
especially at the lower cutting speeds.
In the nal analysis, the cutting forces in machining Ti6Al4V
and Inconel 718 are governed by the interactions among work materials, tool geometry, and the cutting conditions.
Acknowledgement
The support of this study by the U.S. National Science Foundation
under Grant No. 0620792 is greatly appreciated.