In the manufacturing industry, especially defense and aerospace, many component designs and characteristics of titanium materials make them expensive to machine. A considerable amount of stock must be removed from the initial form such as forgings, plates, bars, etc. In some instance, as much as 50 to 90 percent of the primary form's weight ends up as chips. Maximum machining efficiency for titanium alloys is required to minimize the costs of stock removal and maximize productivity. A performance-based methodology of machining optimization has been developed by TechSolve to optimize machining parameters in order to achieve optimum machining performance of machines and cutting tools. This technology has been recently applied in milling operations on titanium alloys. The optimization method has been validated for a dozen of tool-material combinations in face-milling and end-milling operations. Optimum cutting parameters, speeds and feeds, are derived based on the user requirements of the overall machining performance including surface roughness, cutting forces, material removal rate and tool-life. Applications of the machining optimization system can improve process planning, increase productivity and reduce machining cost. A case study will illustrate the optimization of end milling operations on Ti-6Al-4V parts. The comparison of machining performance between pre-technology and post-technology shows that understanding the machining process leads to productivity improvement by optimizing machining parameters without any capital expenditure. It is also a challenge for machining process planners to select appropriate machining parameters for new titanium alloys. Generally, the selection of machining parameters for tooling material combinations is based on experience, handbooks or static databases. However, since there is little experience and little knowledge about the machinability of the new material, process planners will have great difficulties in the selection of machining parameters and cutting tools. Inappropriate machining parameters may cause high scrap rate, short tool life or even tool failure. It will be helpful for process planners if the vendor of the new material could provide a range of safe machining parameters with which they can start process planning. A standard methodology has been developed by TechSolve to evaluate the machinability of new titanium alloys and recommend starting machining parameters for process planners. A case study will illustrate the evaluation of machinability for the new titanium alloy Ti-5-5-5-3 and process planning of end milling operations to produce a part using the obtained machinability information.
展开▼
