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首页> 外文期刊>Proceedings of the Institution of Mechanical Engineers, Part C. Journal of mechanical engineering science >Influence of tool inclination angle and cutting direction on long thin-walled part's dimensional and geometric accuracy when high-speed ball end milling the heat-treated titanium alloy Ti-6Al-4V
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Influence of tool inclination angle and cutting direction on long thin-walled part's dimensional and geometric accuracy when high-speed ball end milling the heat-treated titanium alloy Ti-6Al-4V

机译：热处理钛合金Ti-6Al-4V高速球端铣削时刀具倾角和切削方向对长薄壁零件尺寸和几何精度的影响

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摘要

Thin-walled parts are often used in various industrial applications and due to their functional requirements, higher accuracies are generally desired. But due to their low stiffness characteristics, deformation and chatter problems are frequently encountered in their machining, thus resulting in poor accuracy. Moreover, due to 5-axes milling, which is usually required for finish machining of such parts, further complexities in the process are added and, consequently, achieving higher accuracy becomes more challenging. Therefore, in this study, the influence of tool inclination angle and feeding direction has been investigated on the resultant surface accuracy of thin cantilever shaped parts in finish milling conditions through experiments, finite element method simulations and theoretical discussions. Moreover, since work material's microstructure and hardness also have key influence on its machinability, therefore, the effect of heat treatment state on resulting surface accuracy also has been explored. Three different titanium alloy, Ti-6Al-4V specimens have been used. Two of the specimens were given solution treatment at 1050?/1h followed by aging at 550?/4h. One of the specimens after being solution treated was allowed to cool in air while the other was cooled in water to obtain different microstructure and hardness whereas the third specimen was used in as-received condition (casted). The three Ti-6Al-4V specimens were machined at five different tool inclination angles (60 degrees, 70 degrees, 75 degrees, 80 degrees, and 85 degrees) with two feeding directions (horizontal inwards and vertical inwards). Results have shown that the angle near the perpendicular to the surface i.e. 85 degrees (5 degrees away from the perpendicular) has lowest deformation value and also has better surface quality, which shows that the lowest effective cutting speed at this angle has helped in achieving higher accuracy. Moreover, among the cutting directions studied, vertical inward direction produces smoother surface due to its less pushing effect on the surface being cut as compared to horizontal inwards direction. And in terms of heat treatment state, the specimen which was cooled in air after being solution treated has produced better results for all cutting conditions studied, mainly attributed to fine homogenous lamellar + Ti-6Al-4V structure achieved due to slow cooling rate of air. Analysis of variance using response surface methodology has been carried out to develop predictive model and to study the influence of each variable on the accuracy. The developed model has shown good accuracy when validated through additional experiments.
机译：薄壁零件通常用于各种工业应用中，由于其功能要求，通常需要更高的精度。但是由于它们的低刚度特性，在它们的加工中经常遇到变形和颤动问题，因此导致较差的精度。此外，由于这种零件的精加工通常需要进行五轴铣削，因此增加了加工的复杂性，因此，实现更高的精度变得更具挑战性。因此，在本研究中，通过实验，有限元方法模拟和理论讨论，研究了刀具倾斜角度和进给方向对薄型悬臂成形零件在精铣削条件下所得表面精度的影响。此外，由于工作材料的微观结构和硬度对其可切削性也有关键影响，因此，还探讨了热处理状态对最终表面精度的影响。已经使用了三种不同的钛合金Ti-6Al-4V标本。对两个样品在1050？/ 1h进行固溶处理，然后在550？/ 4h进行时效处理。固溶处理后的一个样品在空气中冷却，而另一个在水中冷却，以得到不同的显微组织和硬度，而第三个样品按原样使用（铸造）。在两个进给方向（水平向内和垂直向内）以五个不同的工具倾斜角度（60度，70度，75度，80度和85度）对三个Ti-6Al-4V样品进行了加工。结果表明，垂直于表面的角度（即与垂直线成85度）的角度最小（变形角度为5度），并且具有更好的表面质量，这表明在该角度下最低的有效切削速度有助于实现更高的切削速度。准确性。此外，在所研究的切削方向中，垂直向内方向产生的表面较光滑，这是因为与水平向内方向相比，其在被切削表面上的推动作用较小。就热处理状态而言，固溶处理后在空气中冷却的试样在所有研究的切削条件下均取得了较好的结果，这主要归因于由于空气的缓慢冷却而实现的细小均匀的层状+ Ti-6Al-4V结构。使用响应面方法进行了方差分析，以开发预测模型并研究每个变量对准确性的影响。经过其他实验验证后，开发的模型显示出良好的准确性。

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