Performance of carbide insert in turning of titanium alloy under carbon dioxide cryogenic cooling

In manufacturing industries, such as aerospace, automotive, chemical and medical, the application of titanium alloys has received more attention, especially in dental implant and orthopedic implant. Although this titanium alloy has a unique characteristics, such as difficulties to machining due to h...

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Main Author: Mat, Siti Asiyah
Format: Thesis
Language:English
English
Published: 2021
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Online Access:http://eprints.utem.edu.my/id/eprint/25985/1/Performance%20of%20carbide%20insert%20in%20turning%20of%20titanium%20alloy%20under%20carbon%20dioxide%20cryogenic%20cooling.pdf
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spelling my-utem-ep.259852022-09-29T12:25:50Z Performance of carbide insert in turning of titanium alloy under carbon dioxide cryogenic cooling 2021 Mat, Siti Asiyah T Technology (General) TJ Mechanical engineering and machinery In manufacturing industries, such as aerospace, automotive, chemical and medical, the application of titanium alloys has received more attention, especially in dental implant and orthopedic implant. Although this titanium alloy has a unique characteristics, such as difficulties to machining due to high hardness, lower thermal conductivity and higher chemical reactivity, this material is always in high demand. During machining of titanium alloy, the major issues frequently discussed are rapid cutting tool wear and generation of high cutting temperature. The proper cooling method needs to be used in order to reduce high cutting temperature that causes rapid tool wear thus increases the tool life of the cutting tool during machining titanium alloy. Many studies have been reported by researchers of cryogenic cooling in machining titanium. In this research, an attempt has been made to investigate the effect of cryogenic cooling using carbon dioxide (CO2) liquid, when it is applied to the workpiece and cutting tool during turning of titanium alloy Ti–6Al–4V ELI. The operation process was carried out using a 3-axis CNC Haas ST-20 lathe machine. Response Surface Methodology (RSM) has been used to design the experiment in determining the effect of the cutting parameters: cutting speed, feed rate and depth of cut towards tool life of the uncoated carbide insert. From RSM, Box-Behnken design has been selected to arrange the cutting parameters of cutting speed with range of 120 to 220 m/min, feed rate with 0.1 to 0.2 mm/rev and depth of cut is 0.4 to 0.6 mm. The flank wear was measured using tool maker microscope. The cutting time values were recorded for each 20 mm on the workpiece until flank wear (Vb) reaches the tool life criterion followed by JIS B4011-1971 standard. From the experiment, the longest tool life recorded is 17.58 minutes obtained at cutting speed 120 m/min, feed rate 0.15 mm/rev and depth of cut 0.40 mm. The shortest tool life is 0.45 minutes obtained at the cutting speed 220 m/min, feed rate 0.15 mm/rev and depth of cut 0.6 mm. The ANOVA analysis showed that for tool life, cutting speed is the most significant factor followed by feed rate and depth of cut to determine and optimise the tool life values. From the detailed observation using SEM, it can be concluded the tool failure mode presents at the cutting tool are flank wear and crater wear. In addition, the observed dominant wear mechanism at the cutting tool is abrasion and adhesion. 2021 Thesis http://eprints.utem.edu.my/id/eprint/25985/ http://eprints.utem.edu.my/id/eprint/25985/1/Performance%20of%20carbide%20insert%20in%20turning%20of%20titanium%20alloy%20under%20carbon%20dioxide%20cryogenic%20cooling.pdf text en public http://eprints.utem.edu.my/id/eprint/25985/2/Performance%20of%20carbide%20insert%20in%20turning%20of%20titanium%20alloy%20under%20carbon%20dioxide%20cryogenic%20cooling.pdf text en validuser https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=121197 mphil masters Universiti Teknikal Malaysia Melaka Faculty of Manufacturing Engineering Sulaiman, Mohd Amri
institution Universiti Teknikal Malaysia Melaka
collection UTeM Repository
language English
English
advisor Sulaiman, Mohd Amri
topic T Technology (General)
TJ Mechanical engineering and machinery
spellingShingle T Technology (General)
TJ Mechanical engineering and machinery
Mat, Siti Asiyah
Performance of carbide insert in turning of titanium alloy under carbon dioxide cryogenic cooling
description In manufacturing industries, such as aerospace, automotive, chemical and medical, the application of titanium alloys has received more attention, especially in dental implant and orthopedic implant. Although this titanium alloy has a unique characteristics, such as difficulties to machining due to high hardness, lower thermal conductivity and higher chemical reactivity, this material is always in high demand. During machining of titanium alloy, the major issues frequently discussed are rapid cutting tool wear and generation of high cutting temperature. The proper cooling method needs to be used in order to reduce high cutting temperature that causes rapid tool wear thus increases the tool life of the cutting tool during machining titanium alloy. Many studies have been reported by researchers of cryogenic cooling in machining titanium. In this research, an attempt has been made to investigate the effect of cryogenic cooling using carbon dioxide (CO2) liquid, when it is applied to the workpiece and cutting tool during turning of titanium alloy Ti–6Al–4V ELI. The operation process was carried out using a 3-axis CNC Haas ST-20 lathe machine. Response Surface Methodology (RSM) has been used to design the experiment in determining the effect of the cutting parameters: cutting speed, feed rate and depth of cut towards tool life of the uncoated carbide insert. From RSM, Box-Behnken design has been selected to arrange the cutting parameters of cutting speed with range of 120 to 220 m/min, feed rate with 0.1 to 0.2 mm/rev and depth of cut is 0.4 to 0.6 mm. The flank wear was measured using tool maker microscope. The cutting time values were recorded for each 20 mm on the workpiece until flank wear (Vb) reaches the tool life criterion followed by JIS B4011-1971 standard. From the experiment, the longest tool life recorded is 17.58 minutes obtained at cutting speed 120 m/min, feed rate 0.15 mm/rev and depth of cut 0.40 mm. The shortest tool life is 0.45 minutes obtained at the cutting speed 220 m/min, feed rate 0.15 mm/rev and depth of cut 0.6 mm. The ANOVA analysis showed that for tool life, cutting speed is the most significant factor followed by feed rate and depth of cut to determine and optimise the tool life values. From the detailed observation using SEM, it can be concluded the tool failure mode presents at the cutting tool are flank wear and crater wear. In addition, the observed dominant wear mechanism at the cutting tool is abrasion and adhesion.
format Thesis
qualification_name Master of Philosophy (M.Phil.)
qualification_level Master's degree
author Mat, Siti Asiyah
author_facet Mat, Siti Asiyah
author_sort Mat, Siti Asiyah
title Performance of carbide insert in turning of titanium alloy under carbon dioxide cryogenic cooling
title_short Performance of carbide insert in turning of titanium alloy under carbon dioxide cryogenic cooling
title_full Performance of carbide insert in turning of titanium alloy under carbon dioxide cryogenic cooling
title_fullStr Performance of carbide insert in turning of titanium alloy under carbon dioxide cryogenic cooling
title_full_unstemmed Performance of carbide insert in turning of titanium alloy under carbon dioxide cryogenic cooling
title_sort performance of carbide insert in turning of titanium alloy under carbon dioxide cryogenic cooling
granting_institution Universiti Teknikal Malaysia Melaka
granting_department Faculty of Manufacturing Engineering
publishDate 2021
url http://eprints.utem.edu.my/id/eprint/25985/1/Performance%20of%20carbide%20insert%20in%20turning%20of%20titanium%20alloy%20under%20carbon%20dioxide%20cryogenic%20cooling.pdf
http://eprints.utem.edu.my/id/eprint/25985/2/Performance%20of%20carbide%20insert%20in%20turning%20of%20titanium%20alloy%20under%20carbon%20dioxide%20cryogenic%20cooling.pdf
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