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Journal articles on the topic 'Difficult-to-cut alloy'

Author: Grafiati

Published: 3 June 2025

Last updated: 13 July 2025

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Hai, Peng, and Ze Fu Bao. "The Honing Technical Research of the Difficult-to-Cut Materials." Key Engineering Materials 416 (September 2009): 426–31. http://dx.doi.org/10.4028/www.scientific.net/kem.416.426.

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The problems occurring in deep hole honing are investigated for the difficult-to-cut materials such as Titanium alloy, high-temperature alloy and stainless steel，and carried out experiments and analyses to select the optimal abrasive honing stone, to improve the honing efficiency and to select rational honing process. The best honing stone types and technological process to those metallic materials have been obtained finally.

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Stupnytskyy, Vadym, and She Xianning. "Research and simulation of the machining process of difficult-to-cut materials." Ukrainian Journal of Mechanical Engineering and Materials Science 6, no. 3-4 (2020): 41–50. http://dx.doi.org/10.23939/ujmems2020.03-04.041.

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Heat-resistant and high-alloy steels and alloys are difficult materials to machine. Optimizing the cutting parameters for such materials is a complex and multi-factorial technological process planning task. The paper describes the method of analysis of loading, thermodynamic and stress-strain state of a workpiece while cutting of typical representative of hard-to-cut materials (chromium-nickel alloy IN718) using finite element simulation. Influence of feed rate on cutting force and temperature in the zone of chip formation is given. The paper also analyzes the effect of cutting edge geometry on the thermal and stress state of the workpiece during cutting. Based on the conclusions about the simulation results, an analogy can be made with the processing of such materials. This will significantly reduce the time of technological preparation and decrease the cost of experimental studies.

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Guan, Xiao Yan, and Ai Sheng Wu. "Experimental Study on Cryogenic Gas Atomization Jet Cooling Difficult-to-Cut Material." Advanced Materials Research 1095 (March 2015): 736–40. http://dx.doi.org/10.4028/www.scientific.net/amr.1095.736.

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Based on pool film boiling, the model of boiling and vaporization to heat transfer is established When droplet jet into cutting zone to cool high temperature wall. Through the transient experiment of cryogenic gas atomization jet cooling high temperature nickel-base alloys and Titanium alloys surface with different water dose. The water dose achieving the best cooling effect is obtained at different temperature on surface of Nickel based alloys and TI-alloy. It is indicated that the water dose to the best cooling effect must be equivalent to the amount of water that materials can vaporize and participate in the phase change heat transfer under certain temperature. When achieving optimal cooling effect, the amount of droplets participating in phase change heat transfer to cool high temperature wall are the most , while comparing the cold air cooling effect and spraying cooling effect at low and high temperature. Result is that either low or high temperature, spraying cooling effect is superior than cold air cooling effect, but at a specific temperature, no lower the temperature of air, the better cooling effect, there is also an optimal air temperature values.

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Ahmed, Naveed, Madiha Rafaqat, Kashif Ishfaq, et al. "Comparison of Laser Milling Performance against Difficult-To-Cut Alloys: Parametric Significance, Modeling and Optimization for Targeted Material Removal." Materials 12, no. 10 (2019): 1674. http://dx.doi.org/10.3390/ma12101674.

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During laser milling, the objective is not always to maximize the material removal rate (MRR). Milling of new material with targeted MRR is challenging without prior knowledge and established sets of laser parameters. The laser milling performance has been evaluated for three important aerospace alloys, i.e., titanium alloy, nickel alloy and aluminum alloy using the response surface method experimental plan (54 experiments for each alloy). Parametric effects of five important laser parameters, statistical analysis (main effects, interaction effects, strength and direction of effects), mathematical modeling and optimality search is conducted for the said alloys. Under the non-optimized laser parameters, the actual MRR significantly varies from the targeted MRR. Variation in the aluminum alloy is at the top as compared to the other two alloys. Among other significant terms, three terms have the largest effect on MRR in the case of TiA, two terms in the case of NiA, and five terms in the case of AlA. Under the optimized sets of laser parameters, the actual material removal highly close to the desired level (100%) can be achieved with minimum variation in all the three alloys. Mathematical models proposed here have the capability to well predict material removal prior to the actual machining of Ti6Al4V, Inconel 718 and AA 2024.

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Xu, Xu Song, Zhi Ying Sun, Zhan Feng Liu, and Hai Peng. "Deep-Hole Precision Honing of Difficult-to-Cut Materials." Advanced Materials Research 690-693 (May 2013): 3218–21. http://dx.doi.org/10.4028/www.scientific.net/amr.690-693.3218.

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For the deep-hole drilling is in closed or half-closed condition and the cutting situation can’t be controlled directly, it brings a big challenge to attain the machining precision. Deep-hole honing is an effective process method that can ensure the precision of size, geometry shape and surface quality. A new machining technologies of finishing honing on precision deep-hole are discussed. Two typical machining examples were illustrated, and the machining effection were also discussed. The key technology and chief feature of strong honing were analyzed through honing experiment of titanium alloy and PH stainless steel. The experiments indicate that strong honing is one effective method to solve the problem of precision deep-hole machining of difficult-to-cut materials and the honing tools which was used in the experiments have the feature of good rigidity, high cutting efficiency.

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Zhang, Feng Quan, and Zhong Han Luo. "Analysis of Processing Equipment for Near-Net Shape Manufacturing Technology of Materials." Advanced Materials Research 572 (October 2012): 390–99. http://dx.doi.org/10.4028/www.scientific.net/amr.572.390.

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The processing equipment for near-net shape technology of materials is introduced in the paper. According to analysis of industrialized processing equipment and technology testing equipment for difficult-to-cut alloy materials, combined with difficulties in strip casting and features of difficult-to-cut alloy materials, the processing equipment for difficult-to-cut alloy materials near-net shaping is developed, thus realized single machine-shaping from molten steel to cold rolling product, and improved near-net shape manufacturing technology of materials.

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Kuczmaszewski, Józef, Kazimierz Zaleski, Jakub Matuszak, Tomasz Pałka, and Rafał Garwacki. "The influence of tool diameter on wear during milling of titanium alloy Ti6Al4V." Mechanik 90, no. 3 (2017): 198–200. http://dx.doi.org/10.17814/mechanik.2017.3.40.

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One of the main problems associated with machining of difficult-to-cut materials is tool wear. Tool wear may comprise a large proportion of production costs. Titanium alloys due to its properties – low thermal conductivity, high durability and a large coefficient of friction belong to difficult-to-cut materials. The paper presents the results of research on the impact of cutter diameter on tool wear during the milling process of titanium alloy Ti6Al4V.

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Zhu, Lin, Peng Hai, and De Ming Xiao. "Experimental Research on Deep Hole Honing of Difficult-to-Cut Materials Based on Mixture-Abrasive Honing Stones." Key Engineering Materials 416 (September 2009): 461–66. http://dx.doi.org/10.4028/www.scientific.net/kem.416.461.

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The deep hole honing is an effective and precise method in deep hole processing. It can remove the machining allowance to ensure the hole size and the shape accuracy, and have better surface quality of a hole. The difficult-to-cut materials such as precipitation-hardening stainless steel, stainless steel (1Cr18Ni9Ti) and titanium alloy have the properties of high hardness, wear resistance, heat resistance, and corrosion resistance. The conventional single-abrasive honing stones can not handle the difficult-to-cut materials effectively because of their single-abrasive property. For higher efficiency, more than ten of mixture-abrasive honing stones with different proportion of different abrasives have been designed and the contrast experiments have been done for different mixture-abrasive honing stones to grind precipitation-hardening stainless steel, stainless steel (1Cr18Ni9Ti) and titanium alloy. According to several comprehensive evaluation factors of the grinding ratio, the specific grinding energy and the area that the honed chips stick the oilstones surface, the optimum proportion of different abrasives have been found for honing difficult-to-cut materials. It can be observed that the mixture-abrasive honing stones have better performance than that of single-abrasive stones when honing certain kind of difficult-to-cut materials.

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Norkey, Gavendra, Avanish Kumar Dubey, and Sanat Agrawal. "Optimization of Multiple Quality Characteristics in Laser Cutting of Difficult-to-Laser-Cut Material." Applied Mechanics and Materials 390 (August 2013): 621–25. http://dx.doi.org/10.4028/www.scientific.net/amm.390.621.

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This paper presents experimental study of laser cutting of Aluminium alloy sheet with the aim to optimize multiple quality characteristics such as cut edge surface roughness and kerf deviation, simultaneously. The Taguchi method combined with Grey relational analysis has been used for parameter optimization. The Principal component analysis and entropy measurement method have been used for eliminating co-linearity and deciding the weighting factors, respectively. The results indicate considerable improvements in multiple quality characteristics.

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Tan, Guang Yu, Guang Jun Liu, Guan Hui Li, Yu Jing Sun, Bao Jun Sun, and Yi Ming Rong. "Research on Adhesion Failure of Milling Insert and Mechanical-Thermal Coupled Field in Milling of Difficult-to-Cut Materials." Materials Science Forum 532-533 (December 2006): 389–92. http://dx.doi.org/10.4028/www.scientific.net/msf.532-533.389.

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The measuring temperature and force experiments of cutting heat-resistance steel (3Cr-1Mo-1/4V alloy and 1Cr18Ni9 alloy) by plane milling insert and milling insert with complex groove that invented by ourselves has been done, meanwhile, the falling process of sticking-welding chip when milling insert cut-in and cut-out has been observed by high-speed photograph. Mechanical-thermal coupled field has been analyzed using ANSYS, and equivalent complex stress of the coupled field is larger than the stress of single field distinctly, it shows that they have a relation of direct proportion. The results of test and analysis show that the main reasons of adhesion failure are heat that produced in cutting process and the change of temperature grads during cut-in or cut-out and alternate tension stress and stress impact during cut-in or cut-out., which provides technical support and experimental data for the groove's optimization and reconstruction of milling insert with 3D complex groove.

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Vozár, M., B. Pätoprstý, and T. Vopát. "Influence of cutting edge microgeometry on the cutting forces when machining difficult-to-cut materials." Journal of Physics: Conference Series 2712, no. 1 (2024): 012025. http://dx.doi.org/10.1088/1742-6596/2712/1/012025.

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Abstract The paper presents research investigating the influence of cutting tools microgeometry on the cutting forces when milling difficult-to-cut materials. Austenitic stainless steel AISI 316L and nickel alloy Inconel 718 were machined with cemented carbide tools with various cutting edge rounding size while measuring the cutting forces during the process. From the standpoint of milling difficult-to-cut materials lowering the cutting forces load on the tool can be difficult to achieve without significant reduction of cutting parameters. Previous research into the cutting edge microgeometry suggests that modification of the cutting edge of milling tools can substantially extend the effective tool life, reduce cutting forces in the process and ensure higher quality of the machined surface. Results of long term wear tests of tools with cutting edge rounding sizes of 15, 30 and 45 µm are compared to the results of a sharp unprepared cutting tool, and the results of each machined material are also compared. Possible influence of cutting edge radius on the process for both materials was tested for cutting conditions constituting finishing operation. The most effective cutting edge radius size differed between the materials, with 15 µm rounding performing the best for AISI 316L and the sharp unprepared tool performing the best for the Inconel 718 alloy.

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Tanaka, Hidetake, and Toma Yoshita. "Machinability Evaluation of Inclined Planetary Motion Milling System for Difficult-to-Cut Materials." Key Engineering Materials 656-657 (July 2015): 320–27. http://dx.doi.org/10.4028/www.scientific.net/kem.656-657.320.

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CFRP and Titanium alloy, which are known as difficult-to-cut materials have been widely used as structural material in aviation industries. The orbital drilling is one of an effective drilling technique for the industries. However this technique has some disadvantages such as increase of cutting force due to cutting with tool center point, inertial vibration generated by revolution and high installation cost. In order to improve the disadvantages, we have invented a new drilling technique which is called inclined planetary motion milling. The inclined planetary motion milling and the planetary mechanism drilling has two axes of cutting tool rotation axis and revolution axis. Cutting tool rotation axis of the orbital drilling is moved parallel to the revolution axis in eccentric. On the other hand, in the case of the inclined planetary motion milling, eccentric of the cutting tool rotation axis is realized by inclination of a few degrees from the revolution axis. Therefore, the movement of eccentric mechanism can be reduced by comparison with the orbital drilling because inclined angle is smaller than eccentricity of the cutting tool tip. As a result, eccentric mechanism can be downsized and inertial vibration is reduced. In the study, a geometrical cutting model of inclined planetary motion milling was set up. The theoretical surface roughness of the inside of drilled holes by use of two types cutting tool geometry were calculated based on the model. And cutting experiments using the new prototype for CFRP were carried out in order to evaluate the effect on machinability with change of cutting point atmosphere. In addition, optimal cutting condition was derived according to cutting experiments for titanium alloys utilizing the orthogonal array.

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Xu, Xu Song, and Zhi Ying Sun. "Study on Small-Diameter Deep–Hole Vibratory Drilling of Difficult-to-Cut Materials." Advanced Materials Research 328-330 (September 2011): 595–99. http://dx.doi.org/10.4028/www.scientific.net/amr.328-330.595.

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To solve the problem of drilling small-diameter deep-hole on difficult-to-cut materials, a kind of DF system combined with low frequency axial vibratory drilling was used. Its vibratory frequency was controlled by a frequency converter and could be adjusted continuously on-line. An inner chip removal deep-hole bit with dimension Φ8.95×500mm was developed and the material of the cutting tip was carbide alloy. Then, the drilling experiment of small-diameter deep-hole on the difficult-to-cut materials 1Cr11Ni4NMo was done. It can be found in the experiment that the chip remove was smooth, the cutting force was little, the cutting tool wear was light, the process of drilling was stable, and many factors of interfering roughness could be canceled or lightened effectively. The results show that DF vibratory drilling system can improve the machining precision and increase efficiency.

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Yang, Hai Dong, Q. J. Zhou, and C. G. Zhang. "Research on the Cutting Mechanism of High-Speed Precision Cutting TC4." Advanced Materials Research 426 (January 2012): 283–86. http://dx.doi.org/10.4028/www.scientific.net/amr.426.283.

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In this paper, TC4 (Ti6Al4V) alloy has been cut at high speed minutely .Chip roots is extracted by rapid knife device. The optical microscopic image of the root chip is analyzed. The reasons why it is difficult to cut for TC4 alloy are firstly due to the low ability for heat transfer, while the second one maybe the cutting path is mainly the trans-granular failure which will consume more energy due to the coarse grains of TC4 alloy.

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Thamizhmanii, Sivaprakasam, and Hasan Sulaiman. "Machinability Study Using Chip Thickness Ratio on Difficult to Cut Metals by CBN Cutting Tool." Key Engineering Materials 504-506 (February 2012): 1317–22. http://dx.doi.org/10.4028/www.scientific.net/kem.504-506.1317.

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Machinability is the one of the criteria in determining the life of the cutting tool. In this experiment, hard and difficult to cut materials like hard AISI 440 C stainless steel and hard SCM 440 alloy steels were discussed. However, machinability of the material is considered to be poor due to its inherent characteristics. The machinability studies on AISI 440 C stainless steel and SCM 440 alloy steels had not been carried out by researchers. Machinability indices used in such cases have the characteristics such as cutting force, surface roughness, tool wear etc. In the case of high-speed machining of said materials machinability indices such as chip thickness (RC), shear angle (Ф), surface integrity, and chip analysis are of prime importance. Most of the researchers have not given due consideration to these vital machinability indices necessary for understanding of high-speed cutting of said materials. In this work, an experimental investigation was carried out to understand the behavior of difficult to cut materials, when machined with Cubic Boron Nitride (CBN) insert tool. The results and analysis of this work indicated that the above-mentioned machinability indices are important and necessary to assess the machinability of said materials effectively. The operating parameters used were cutting velocity 100, 125, 150, 175 and 200 m/min with feed rate of 0.10, 0.20 and 0.30 mm rev-1 with constant depth of cut of 1.0 mm. The length of turning was 150 mm and 300 mm. Machinability of both materials and tool was evaluated in terms of roughness, flank wear, cutting force, chip thickness ratio and shear angle.

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Yue, Yuxiao, Yumei Zhu, and Zhihong Li. "Preparation and cutting performance study of YSZ-toughened PcBN superhard tools." RSC Advances 13, no. 23 (2023): 15616–23. http://dx.doi.org/10.1039/d3ra02079g.

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Nikawa, Makoto, and Masato Okada. "Investigation of Machinability in Milling of Difficult-to-Cut Materials Using Water Soluble and Water Insoluble Cutting Oil." Key Engineering Materials 656-657 (July 2015): 308–13. http://dx.doi.org/10.4028/www.scientific.net/kem.656-657.308.

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The machinability of difficult-to-cut materials was evaluated during the milling process using water soluble and water insoluble cutting oils. The fundamental characteristics of the cutting oils were investigated by the pin-on-disk abrasion test. The machinability was evaluated by the tool flank wear, chip geometry, cutting force, and tool-flank temperature during milling. The tool-flank temperature was measured using a two-color pyrometer with an optical fiber. Workpiece materials consisting of stainless steel and a titanium alloy were used along with commercial cutting oils. From the results of the pin-on-disk abrasion test, the friction coefficients resulting from the application of various cutting oils to the face of the titanium alloy and WC-based hard metal were approximately the same value. The water soluble cutting oil had a higher coolability than the water insoluble cutting oil. From the results of the milling test, the water insoluble oil had a higher machinability of the difficult-to-cut materials than the water soluble cutting oil. The tool-flank temperature during wet cutting of the difficult-to-cut materials decreased by approximately 50–80 °C compared to dry cutting. However, no differences in the tool-flank temperature were observed between the water soluble and water insoluble cutting oils. The cutting force during wet cutting increased compared to dry cutting, most likely because the heating during cutting was reduced by supplying the cutting oil, and the material at the cutting point did not cause heat softening.

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Ferreira, Pedro, Fernando Simões, and Carlos Relvas. "Experimental Analysis of Milling Operations in Ti-6Al-4V and Co-28Cr-6Mo Alloys for Medical Devices." Key Engineering Materials 611-612 (May 2014): 1282–93. http://dx.doi.org/10.4028/www.scientific.net/kem.611-612.1282.

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In order to understand the problems that arising during machining and contribute to find the best way to produce medical prosthesis, an experimental milling analysis was conducted in Ti-6Al-4V and Co-28Cr-6Mo alloys. The thermal gradient and the cutting forces created on the surface during the machining were evaluated for different cutting speeds. Moreover, the roughness and Vickers hardness were evaluated. Based on the results obtained, it is possible to conclude that the difficult to cut of Co-28Cr-6Mo alloy is higher than Ti-6Al-4V alloy.

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Li, Shiyu, Jinguo Han, Haiqiang Yu, et al. "Finite Element Investigation on Cutting Force and Residual Stress in 3D Elliptical Vibration Cutting Ti6Al4V." Micromachines 13, no. 8 (2022): 1278. http://dx.doi.org/10.3390/mi13081278.

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Titanium alloy is a typical difficult-to-machine material with features of superhigh strength and hardness, and low elastic modulus. It is difficult to guarantee the processing quality and efficiency due to the high cutting force and tool wear in conventional cutting. Elliptical vibration cutting (EVC) as an effective method can improve the machinability of titanium alloys. In this paper, the finite element method (FEM) was adopted to study the cutting force and residual stress of 3D EVC in machining of Ti6Al4V. The Johnson-Cook constitutive model was utilized to illustrate the plastic behavior of Ti6Al4V alloy. The kinematics of the 3D EVC was described, and then the influence of various cutting speeds, vibration amplitudes, vibration frequencies and depths of cut on cutting force and residual stress were carried out and analyzed. The simulation results show that the cutting speed, vibration amplitude a, vibration frequency and depth of cut have larger effect on principal force. In addition, the compressive stress layer can be easily obtained near the machined surface by using 3D EVC, which is helpful to improve the working performance of workpiece.

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Ibrahim, Gusri Akhyar, Che Hassan Che Haron, and Jaharah A. Ghani. "Tool Wear Mechanism in Continuous Cutting of Difficult-to-Cut Material under Dry Machining." Advanced Materials Research 126-128 (August 2010): 195–201. http://dx.doi.org/10.4028/www.scientific.net/amr.126-128.195.

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Wear mechanism on the flank of a cutting tool is caused by friction between newly machined surface and the cutting tool, which plays predominant role in determining tool life. Detailed study on wear mechanism at the cutting edge of carbide tools were carried out at cutting speed of 55 – 95 m/min, feed rate of 0.15 – 0.35 mm/rev and depth of cut of 0.10 – 0.20 mm. The wear on the cutting tools was occurred predominantly on the nose radius, as effect of lower feedrate and nose radius selected. Various wear observed on both coated and uncoated cutting tool such as abrasive wear, adhesive wear, adhering chip on the cutting edge, flaking, chipping, coating delamination of coated tool, crack and fracture. The abrasive wear predominantly occurred on the flank face while the flaking on the rake face. Abrasive wear occurred at nose radius due to the depth of cut selected was low therefore, the contact area between the cutting tool and the workpiece material was small. Adhesion or welded titanium alloy onto the flank and rake faces demonstrated a strong bond at the workpiece-tool interface. The adhesion wear takes place after the coating has worn out or coating delamination has been occurred. The crack occurred possibly due to machining at high cutting speed and high depth of cut. Cutting at high cutting speed caused more heat generated at the cutting edge and at high depth of cut caused more cutting forces on the insert.

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Ślusarczyk, Łukasz, and Andrzej Matras. "Influence of Cutting Data on the Thin Wall Deformation in Milling of Difficult to Cut Materials." Key Engineering Materials 686 (February 2016): 86–91. http://dx.doi.org/10.4028/www.scientific.net/kem.686.86.

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The paper presents the results of milling tests of aluminum alloy with a sintered carbide tool. For selected sets of cutting data, the thin wall deformation of the workpieces was analyzed. Theoretical calculations were compared with the experimental measurements, using the high speed camera and FEM analysis.

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Pothur, Hema, Ramprasad Ganesan, and K. Aruna. "Experimental Investigations on Inconel 625 Alloy Using Plasma Arc Machining." International Journal of Manufacturing, Materials, and Mechanical Engineering 10, no. 4 (2020): 40–57. http://dx.doi.org/10.4018/ijmmme.2020100104.

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Plasma arc machining (PAM) is a non-traditional machining process widely used to machine intricate part profiles for alloys that are difficult to machine. The Burr height, Kerf ratio, and material removal rate (MRR) are predominant factors that influences the performance and quality of plasma cut surfaces. Present research focusses on the effect of plasma arc cutting (PAC) parameters such as gases used, cutting speed, current, arc voltage, and gas pressure on the cut quality characteristics of Inconel 625 alloy. The design of experiments (DOE) technique is used to develop a Taguchi design consisting of L18 orthogonal array. The Grey relational analysis technique is used for optimization of the above said cutting conditions. Finally, the most suitable gas to machine is selected along with the optimal PAM parameters for cutting the Inconel 625 alloy. Scanning electron microscope (SEM) analysis is carried out to inspect the surface morphologies at various cutting conditions.

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Liao, Yunn Shiuan, and Chin Nan Chen. "A Study of a Strategy for Threading Titanium Alloy." Advanced Materials Research 753-755 (August 2013): 323–32. http://dx.doi.org/10.4028/www.scientific.net/amr.753-755.323.

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The cutting of precision threads is an important manufacturing process. Several passes are needed to complete the cutting of a thread and the choice of appropriate cutting speed and depth of cut for each cutting pass is essential. The cutting efficiency and tool life are significantly affected by these two parameters, especially when cutting threads in difficult-to-cut materials, such as titanium alloy. This paper proposes the concept of an equal undeformed chip area for all cutting passes, in order to determine the depth of cut for each pass. The principal goal is to maintain the same cutting force throughout the cutting process. Using tool geometry, the relationship between the cumulative depth of cut and the undeformed chip area for each cutting pass are derived. The depth of cut of each corresponding cutting pass can be determined, once the dimensions of the thread and the number of cutting passes are specified. Experiments were conducted to cut an ISO metric screw thread, with a pitch of 0.5 mm, on a 40 mm in diameter bar. It was found that, for the same total number of cutting passes, the tool wear was less than that suggested by the tool makers, when a depth of cut for each pass was determined using the proposed method. The thread could be cut using a higher cutting speed, resulting in a much shorter machining time. In addition, the proposed strategy also allowed completion of cutting using less cutting passes. A 25% increase in efficiency was noted for the specific thread used in the experiment.

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Beranoagirre, Aitor, Gorka Urbikain, Amaia Calleja та Luis López de Lacalle. "Drilling Process in γ-TiAl Intermetallic Alloys". Materials 11, № 12 (2018): 2379. http://dx.doi.org/10.3390/ma11122379.

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Gamma titanium aluminides (γ-TiAl) present an excellent behavior under high temperature conditions, being a feasible alternative to nickel-based superalloy components in the aeroengine sector. However, considered as a difficult to cut material, process cutting parameters require special study to guarantee component quality. In this work, a developed drilling mechanistic model is a useful tool in order to predict drilling force (Fz) and torque (Tc) for optimal drilling conditions. The model is a helping tool to select operational parameters for the material to cut by providing the programmer predicted drilling forces (Fz) and torque (Tc) values. This will allow the avoidance of operational parameters that will cause excessively high force and torque values that could damage quality. The model is validated for three types of Gamma-TiAl alloys. Integral hard metal end-drilling tools and different cutting parameters (feeds and cutting speeds) are tested for three different sized holes for each alloy.

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Liu, Zhanfeng, Yanshu Liu, Xiaolan Han, and Wencui Zheng. "Study on super-long deep-hole drilling of titanium alloy." Journal of Applied Biomaterials & Functional Materials 16, no. 1_suppl (2018): 150–56. http://dx.doi.org/10.1177/2280800017751491.

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Introduction: In this study, the super-long deep-hole drilling of a titanium alloy was investigated. Methods: According to material properties of the titanium alloy, an experimental approach was designed to study three issues discovered during the drilling process: the hole-axis deflection, chip morphology, and tool wear. Results: Based on the results of drilling experiments, crucial parameters for the super-long deep-hole drilling of titanium alloys were obtained, and the influences of these parameters on quality of the alloy’s machining were also evaluated. Conclusions: Our results suggest that the developed drilling process is an effective method to overcome the challenge of super-long deep-hole drilling on difficult-to-cut materials.

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Zhu, Lin, and Jiang Ping Wang. "A Study on Titanium Alloys Deep-Hole Drilling Technique." Materials Science Forum 532-533 (December 2006): 945–48. http://dx.doi.org/10.4028/www.scientific.net/msf.532-533.945.

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Focusing on the difficult-to-cut characteristic of titanium alloy, this paper selects several cemented carbide tool materials in the tests of machining the titanium alloy workpieces. Different sets of geometrical parameters of the drilling bits are grouped, chosen and optimized, and then deep-hole drilling tests are carried out. The suitable cutter materials and the optimum geometrical parameters of the cutter for drilling deep holes in titanium alloy have been determined through the analysis of tested results.

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Wakabayashi, Toshiaki, Keisuke Yamada, Shota Koike, and Toshifumi Atsuta. "Turning of Titanium Alloy Using Near-Dry Methods with MQL, Coolant Mist and Hybrid Mist Supplies." Key Engineering Materials 749 (August 2017): 101–6. http://dx.doi.org/10.4028/www.scientific.net/kem.749.101.

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Because of effective machining operations with a very small amount of cutting fluids, near-dry machining attracts increasing attentions for environmental and economical benefits. MQL machining has so far been recognized as the most representative near-dry method and it is highly successful in machining of most ordinary steels. Recent concern for environmentally friendly manufacturing further encourages the attempts at applying near-dry operations to machining of difficult-to-cut materials. Since titanium alloys are typical difficult-to-cut materials, this paper investigates the cutting performance of various near-dry methods in turning of a titanium alloy from the view point of elongating the tool life. Those near-dry operations include supply methods of regular MQL mist, coolant mist and hybrid mists, where the coolant mist is atomized water-soluble cutting fluid and hybrid mists are the mixture of MQL and coolant mists. The regular MQL operation provided longer tool life than that of dry machining. In addition, compared with MQL machining, the hybrid mist operations could further extend tool life and, in particular, the single coolant mist operations demonstrated the possibility of making the tool life longer than that of ordinary wet machining with flood cutting fluid supply.

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Wakabayashi, Toshiaki, Junji Kuhara, Toshifumi Atsuta, et al. "Near-Dry Machining of Titanium Alloy with MQL and Hybrid Mist Supply." Key Engineering Materials 656-657 (July 2015): 341–46. http://dx.doi.org/10.4028/www.scientific.net/kem.656-657.341.

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Near-dry machining attracts increasing attentions for environmental and economical benefits, and MQL machining has been recognized as the most representative near-dry method. It is highly successful in machining of most ordinary steels, and synthetic biodegradable polyol esters play a significant role as an effective cutting fluid with a very small amount. Recent concern for environmentally friendly manufacturing further encourages the attempts at applying near-dry operations to machining of difficult-to-cut materials. Since titanium alloys are typical difficult-to-cut materials, this paper investigates the cutting performance of various near-dry methods in turning of a titanium alloy from the view point of elongating the tool life. Those near-dry methods include regular MQL and hybrid mist supply operations, where the hybrid mist is a mixture of MQL mist and coolant mist which is atomized water-soluble cutting fluid. The regular MQL operation provided considerably long tool life compared with that of dry machining and the hybrid mist operation showed the possibility of making the tool life longer. The cutting performance was largely influenced by the type of MQL lubricants. In particular, a synthetic polyol ester lubricant having low viscosity indicated the successful cutting performance when it was combined with the coolant mist supply in the hybrid mist application.

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Han, Rong Di, Yue Zhang, Yang Wang, Guo Fan Cao, and Jie Liu. "The Effect of Superheated Water Vapor as Coolant and Lubricant on Chip Formation of Difficult-to-Cut Materials in Green Cutting." Key Engineering Materials 375-376 (March 2008): 172–76. http://dx.doi.org/10.4028/www.scientific.net/kem.375-376.172.

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Green cutting is ecologically desirable and have been a tendency in the industry field. Water vapor can be introduced in metal cutting as coolant and lubricant due to its pollution-free, generating easily and unneeded disposal. Therefore, water vapor is an environment-friendly coolant and lubricant in machining. This study attempts to understand the effect of water vapor as coolant and lubricant on chip formation. In the comparison experiments to dry and wet cutting, water vapor jet flow from a developed generator is applied into cutting zone directly. When YG8 (K20 in ISO) tools are used to turn titanium alloy TC4 (Ti-6Al-4V), Ni-based super alloy GH3030 and stainless steel 1Cr18Ni9Ti in orthogonal cutting, through quick-stop tests, the photos of polished chip sections microstructure were obtained. And the results suggest that the application of water vapor produces the least BUE, tool-chip contact length but the largest deformation coefficient and shear angle. The water vapor as coolant and lubricant could be a substitution of cutting fluid to carry out green cutting in the machining of difficult-to-cut materials.

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Xu, Hong Hai, Qian Xu, and Dong Liu. "Experimental Study on Milling Force of High-Temperature Alloy GH536." Advanced Materials Research 97-101 (March 2010): 1929–32. http://dx.doi.org/10.4028/www.scientific.net/amr.97-101.1929.

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High-temperature alloy GH536 is a difficult-to-cut material. The paper finished milling experiment of GH536 with cemented carbide tool based on orthogonal test, obtained regulations between milling force and feed speed, cutting depth and spindle speed. Results indicate that the milling force increases with feed speed and cutting depth, decreases with spindle speed. Exponential formulas of milling force were obtained by SPSS, variance analysis showed it agreed well with experimental data.

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Słodki, Bogdan, Wojciech Zębala, and Grzegorz Struzikiewicz. "Turning Titanium Alloy, Grade 5 ELI, With the Implementation of High Pressure Coolant." Materials 12, no. 5 (2019): 768. http://dx.doi.org/10.3390/ma12050768.

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In the machining of difficult-to-cut alloys, such as titanium-based alloys, the delivery of a cutting fluid with high pressure can increase machining efficiency and improve process stability through more efficient chip breaking and removing. Proper selection of machining conditions can increase the productivity of the process while minimizing production costs. To present the influence of cutting fluid pressure and chip breaker geometry on the chip breaking process for various chip cross-sections Grade 5 ELI titanium alloy turning tests were carried out using carbide tools, H13A grade, with a -SF chip breaker geometry under the cutting fluid pressure of 70 bar. Measurements of the total cutting force components for different cutting speeds, feeds, and cutting depth in finishing turning were carried out. The analysis of the obtained chips forms and the application area of the chip breaker have been presented. It was proved that for small depth of cut (leading to small chip cross-section) the cutting fluid pressure is the main cause of the chip breakage, since the insert chip breaker does not work. On the other hand, for bigger depths of cut where the chip breaker goes in action, the cutting fluid pressure only supports this process. For medium values of depths of cut the strength of chip is high enough so that the pressure of the cutting fluid cannot cause chip breaking. A chip groove is not filled completely so the chip breaker cannot play its role.

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Zhao, ZeJia, Suet To, and ZhuoXuan Zhuang. "Serrated Chips Formation in Micro Orthogonal Cutting of Ti6Al4V Alloys with Equiaxial and Martensitic Microstructures." Micromachines 10, no. 3 (2019): 197. http://dx.doi.org/10.3390/mi10030197.

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The formation of serrated chips is an important feature during machining of difficult-to-cut materials, such as titanium alloy, nickel based alloy, and some steels. In this study, Ti6Al4V alloys with equiaxial and acicular martensitic microstructures were adopted to analyze the effects of material structures on the formation of serrated chips in straight line micro orthogonal machining. The martensitic alloy was obtained using highly efficient electropulsing treatment (EPT) followed by water quenching. The results showed that serrated chips could be formed on both Ti6Al4V alloys, however the chip features varied with material microstructures. The number of chip segments per unit length of the alloy with martensite was more than that of the equiaxial alloy due to poor ductility. Besides, the average cutting and thrust forces were about 8.41 and 4.53 N, respectively, for the equiaxed Ti6Al4V alloys, which were consistently lower than those with a martensitic structure. The high cutting force of martensitic alloy is because of the large yield stress required to overcome plastic deformation, and this force is also significantly affected by the orientations of the martensite. Power spectral density (PSD) analyses indicated that the characteristic frequency of cutting force variation of the equiaxed alloy ranged from 100 to 200 Hz, while it ranged from 200 to 400 Hz for workpieces with martensites, which was supposedly due to the formation of serrated chips during the machining process.

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Bordin, Alberto, Stano Imbrogno, Stefania Bruschi, Andrea Ghiotti, and Domenico Umbrello. "Numerical Modelling of Orthogonal Cutting of Electron Beam Melted Ti6Al4V." Key Engineering Materials 651-653 (July 2015): 1255–60. http://dx.doi.org/10.4028/www.scientific.net/kem.651-653.1255.

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Finite element analysis of cutting processes of difficult-to-cut alloys is attracting more and more interest among the scientific community thanks to the change of predicting difficult to measure parameters as cutting forces, specific cutting pressures, cutting temperatures and the chip morphology. Aiming at calibrating and validating an FE numerical model, the predicted variables have to be compared with experimental results. Nowadays, Additive Manufactured Titanium alloys are being increasingly employed in the production of surgical implants and aero engine parts, but their peculiar fine acicular microstructure have to be taken into account dealing with their thermo-mechanical behavior as during machining operations. Based on the lack of literature works concerning experimental investigations on the machinability of Additive Manufactured Titanium alloys, this paper is aimed at investigating the cutting forces and temperatures arising during orthogonal cutting of an Electron Beam Melted (EBM) Ti6Al4V alloy.

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Tsuda, Koji, Koichi Okuda, Hiroo Shizuka, and Masayuki Nunobiki. "A Study of the Micro-End Milling of Titanium Alloy." Advanced Materials Research 325 (August 2011): 588–93. http://dx.doi.org/10.4028/www.scientific.net/amr.325.588.

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This study deals with the cutting characteristics of titanium materials when milled by a small-diameter end mill, or a micro end mill. It is well known that titanium is difficult to cut by conventional means. However, its cutting characteristics have not yet been made sufficiently clear in cases where a micro end mill less than 1 mm in diameter is used. This study chiefly involves the experimental investigation of tool wear and surface roughness of micro-end milling of Ti-6Al-4V. The findings were that tool wear did not increase much when the cutting speed was increased from 50 m/min to 200 m/min. Furthermore, the cutting force required to cut decreased at high speeds and during wet cutting. In wet cutting, the surface had a roughness (Rz) of only 0.3 μm at 200 m/min in contrast to 0.6 μm at 50 m/min.

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Vasudevan, Hari, Ramesh Rajguru, Moeiz Shaikh, and Arsalan Shaikh. "Optimization of Process Parameters in the Turning Operation of Inconel 625." Materials Science Forum 969 (August 2019): 756–61. http://dx.doi.org/10.4028/www.scientific.net/msf.969.756.

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Many difficult to machine materials, such as Inconel 625Ni-based super alloy, are uncommon class of metallic materials with exceptional combination of greater thermal strength, toughness and resistance to deterioration. They have extensive applications in the manufacturing of new aero-engines, besides its enormous uses in marine, chemical and oil & petrochemical industries. In the context of its wide range of applications, there is a need for efficiently processing better methods in the manufacturing of such difficult to machine materials. This study consists of the turning operation of Ni-based super alloy Inconel 625 without coolant, carried out by physical vapour deposition (PVD) coated carbide inserts. The response parameters, such as surface roughness and material removal rate were evaluated in terms of cutting speed, feed rate and depth of cut. Sixteen experiments were carried out, based on Taguchi's Design of Experiments using orthogonal array. The resulting analysis was done based on response graph. The experimental results revealed that the feed rate was the most influential factor, followed by the depth of cut and cutting speed. The optimal parameters achieved were cutting speed of 90 m/min, the feed rate of 0.35 mm/rev and the depth of cut 0.2 mm.

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Okada, Masato, Makoto Nikawa, Ryutaro Tanaka, and Naoki Asakawa. "Effects of Supplying Oil Mist and Water Mist with Cold Air on Cutting Force and Temperature in End Milling of Difficult-to-Cut Materials." Key Engineering Materials 656-657 (July 2015): 255–60. http://dx.doi.org/10.4028/www.scientific.net/kem.656-657.255.

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This paper discusses the cutting temperature and cutting force in end milling difficult-to-cut materials cooled with several types of mists and low-temperature air. The cutting tool was a throwaway end mill with a carbide tip coated with titanium aluminum nitride. The Ti-6Al-4V titanium alloy and AISI D2 hardened steel were used as workpieces. The tool flank temperature and cutting force were measured simultaneously during side milling. The temperature was measured using a two-color pyrometer with an optical fiber. Oil mist and water mist from a mist generator were supplied to the cutting point along with cold air at approximately -27 °C. Compared with dry cutting, the cooling effects of supplying an oil mist and/or cold air were less than for other supply conditions in titanium alloy cutting. However, when water mist was added, the tool flank temperature clearly decreased. The cutting force increased for cases that included water mist. The adhesion of the titanium alloy to the cutting edge of the worn tool was significantly suppressed by supplying water and oil mist with cold air. Tool flank wear also decreased under those lubrication conditions.

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Zhu, Zhao Ju, Jie Sun, and Lai Xiao Lu. "Research on the Influence of Tool Wear on Cutting Performance in High-Speed Milling of Difficult-to-Cut Materials." Key Engineering Materials 693 (May 2016): 1129–34. http://dx.doi.org/10.4028/www.scientific.net/kem.693.1129.

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A series of research on the interactions among tool wear, cutting force and cutting vibration were conducted through high speed milling experiment in this paper, which objected the titanium alloy as difficult-to-cut materials. The results showed that the increasing of tool wear led to enlarging the cutting force and cutting vibration; and vice versa, the increasing of cutting force and cutting vibration aggravated the tool wear in the process of machining. Besides, the variation trend of tool wear with cutting was similar to the trend of cutting force, while the variation trend between cutting vibration and tool wear was different. Especially in the sharply cutting tool wear stage, the influence of tool wear on cutting vibration became more complicated.

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Kumar, N. E. Arun, A. Suresh Babu, and V. Muthu Kumar. "Parametric Study along with Selection of Optimal Solutions in Wire Cut Machining of Titanium (Gr2)." Advanced Materials Research 984-985 (July 2014): 37–41. http://dx.doi.org/10.4028/www.scientific.net/amr.984-985.37.

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This paper investigates the relationship of process parameters in wire electrical discharge machining of titanium alloy with brass wire as tool electrode. Wire electrical discharge machining (WEDM) is used to cut conductive metals of any hardness or that difficult to cut with conventional methods. The process performances such as material removal rate (MRR) and surface finish (Ra) were evaluated by giving specific input parameters which practiced to obtain optimal response. The difficulty in machine tool industry is to predict the expected output performance for the desired input variables by the way of conducting more number of experiments for different machining parameters, which leads to the increase in consumption of electric power, material and time. To overcome this phenomenon, parametric investigation was made on WED machining on titanium alloy by using Taguchi’s method.

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Sulaiman, S., A. Roshan, and S. Borazjani. "Finite Element Modeling and Simulation of Machining of Titanium Alloy and H13 Tool Steel Using PCBN Tool." Applied Mechanics and Materials 392 (September 2013): 36–40. http://dx.doi.org/10.4028/www.scientific.net/amm.392.36.

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This paper deals with finite element modeling (FEM) and simulation of machining of titanium alloy and H-13 tool steel. Titanium alloys are very suitable for airframe manufacture and aircraft as H-13 uses forging dies and machined die casting. The machinability of both metals was evaluated by high temperature and tool wear. Finite element simulation was performed with ABAQUS explicit software to predict cutting temperature and stress distribution during metal cutting process. The purpose of this study was evaluation the performance of PCBN cutting tool material on machining of titanium alloy and H-13. It was found that PCBN tool can resistant well against high thermal shocks, high temperature and stress distribution when machining difficult to cut materials. The results can give a better understanding of cutting tool material for metal cutting process.

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Enzi, Abass, Ahmed Ghazi Abdulameer, Omar Hashim Hassoon, and Abdallah Hamieh. "Experimental Investigation of Manufacturing Variables Effect on Electrical Discharge Machining of Titanium Alloy." Management Systems in Production Engineering 33, no. 2 (2025): 202–11. https://doi.org/10.2478/mspe-2025-0019.

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Abstract Titanium alloys are considered one of the materials required in industries. They can be used in various fields due to their high strength and corrosion resistance, but titanium alloys are considered difficult to machine using traditional methods. EDM is used to machine a workpiece using electrical discharges to cut hard materials that are challenging to cut with traditional methods. Therefore, this paper focuses on the machine of a high-strength material-titanium alloy Ti-6Al-4V and studies the influence of cutting process variables on the metal removal rate, tool wear rate, and surface roughness of the samples. The samples matrix form is created depending on the design of experiments method. Pulse-on time, discharge current, and gap process variables with three levels create mathematical models to predict the responses without conducting practical experiments. The results proved that machining variables impacted the responses, which were proven through results data analysis and the interaction plots. Also, the maximum error between experimental and predicted values using the mathematical model was 0.022 (mg/min) for the MRR, 1.719 (mg/min) for the TWR, and 0.334 (μm) for the Ra.

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Chenrayan, Venkatesh, Chandru Manivannan, Kiran Shahapurkar, et al. "Machinability Performance Investigation of TiAlN-, DLC-, and CNT-Coated Tools during Turning of Difficult-to-Cut Materials." Journal of Nanomaterials 2022 (November 28, 2022): 1–15. http://dx.doi.org/10.1155/2022/9664365.

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Titanium alloy-based components are now attracted by the industries with their distinguished properties even though they are difficult to machine. The tooling industries encounter numerous problems in machining these metals like higher tool wear, huge volumes of cutting fluid consumption, and shorter tool life. The objective of this research is to enhance the surface of the cutting tool with carbon nanotube (CNT) deposition to solve the aforementioned difficulties. This research used the plasma-enhanced chemical vapor deposition method to coat CNT on high-speed steel tools. Microstructural investigations were performed using a scanning electron microscope and a Raman spectroscopic technique to ensure the homogenous deposition of CNT. Additionally, scratch testing was also conducted to assess the adhesive strength of the deposited layer to the substrate. Finally, the machining performance of the CNT-coated tool was compared with commercially available diamond-like carbon (DLC) and titanium aluminum nitride (TiAlN)-coated tools. Machining experiments conducted under three distinct cutting levels revealed that the CNT-deposited tool is appropriate for turning more challenging materials. CNT-coated tools showed substantial decreases in cutting tooltip temperature, turning forces, and tool wear compared to DLC and TiAlN-coated tools. In particular, tool life studies conducted under elevated machining circumstances recorded the enhancement in tool life as 96.3% and 26.8% in comparison with TiAlN and DLC, respectively.

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Mannan Basha, S., B. C. Raghu kumar Reddy, and T. Vishnu Vardhan. "Optimization of Cutting Parameters in High Speed Turning of Nickel Alloy." Asian Journal of Science and Applied Technology 2, no. 2 (2013): 5–13. http://dx.doi.org/10.51983/ajsat-2013.2.2.762.

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Inconel 718 is one of the important alloys among all the Nickel and Nickel based alloy Inconel 718 has found its niche in many industries, owing to its unique properties. Inconel 718 material is widely used in as aircraft engine parts, steam turbine power plants, space vehicles, But due to peculiar characteristics such as lower thermal conductivity, work hardening, presence of abrasive carbide particles it difficult to machine, Cost effective machining with generation of good surface finish on the Inconel 718 components during turning operation is a challenge to the manufacturing engineers in practice. Considering all the above facts the present work aims to study the influence of different cutting parameters like cutting speed, feed rate and depth of cut of super alloy Inconel 718 and AISI 52100 Steel during high speed turning. Test results were analyzed to determine the better parameters for optimal cutting during high speed machining of Inconel 718 cubic boron nitride tool. A parametric model of cutting tool and work piece is designed using 3D modelling software Pro/Engineer. Analytical investigations are to be made on the model by applying the forces by taking different values of cutting speed, feed rate and depth of cut. Analysis is done in Ansys.

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Zhang, Yue, Li Han, Qi Dong Li, Tai Li Sun, and Xi Chuan Zhang. "Machining Process of Titanium Alloy Based on Green Cooling and Lubricating Technology." Advanced Materials Research 139-141 (October 2010): 681–84. http://dx.doi.org/10.4028/www.scientific.net/amr.139-141.681.

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The machining process of titanium alloys always need special control by using coolant and lubricant as it is one of the difficult-to-cut materials. To achieve green cutting of titanium alloy Ti-6Al-4V with water vapor cooling and lubricating, a minitype generator is developed. Compared to dry and wet cutting, the using of water vapor decreases the cutting force and the cutting temperature respectively; enhances the machined surface appearance. Water vapor application also improves Ti-6Al-4V machinability. The excellent cooling and lubricating action of water vapor could be summarized that water molecule has polarity, small diameter and high speed, can be easily and rapidly to proceed adsorption in the cutting zone. The results indicate that the using of water vapor has the potential to attain the green cutting of titanium alloy instead of cutting floods.

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Karim, A. N. Mustafizul, M. Ikram, H. M. Emrul Kays, M. Abdesselam, and T. L. Ginta. "Assessment of Machining Cost for End-Milling of Ti-6Al-4V Titanium Alloy through RSM-Based Parametric Model." Advanced Materials Research 903 (February 2014): 83–89. http://dx.doi.org/10.4028/www.scientific.net/amr.903.83.

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Past few decades have been marked by significant achievements in the development of cutting tools and machining processes. End-milling operation with Polycrystalline Diamond (PCD) cutting tool insert presents a good technical solution for machining difficult-to-cut materials. However, the cost of each technical or technological solution is a major concern in the decision making process. It is quite common for a solution developer to encounter a question like How much will this new method cost? before proceeding for implementation. PCD insert applied as a cutting tool is a recent development and evaluation of economic performance of this cutting tool insert in end-milling of a-difficult-to-cut material such as Ti-6Al-4V titanium alloy can be of significant importance to the manufacturer. However, cost economy depends significantly on the correct choice of cutting conditions especially in the context of cutting parameters. To determine the economically desired levels of the cutting parameters for PCD insert to end-mill Titanium alloy we have presented a RSM-based mathematical model which would help to estimate the cost of removing unit volume of material and to find out the optimum cutting conditions leading to minimum machining cost.

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Kumar, G. Venkata Ajay, M. Shilpa, Udagave Shital Purander, G. Madhoo, and V. Asokan. "Multi-Objective Optimization of Machining Process Parameters in Wire-Cut Electric Discharge Machining of Inconel X750 Alloy by Combinatorial Approach." Materials Science Forum 969 (August 2019): 781–86. http://dx.doi.org/10.4028/www.scientific.net/msf.969.781.

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Difficult-to-cut materials, generally high hardness, strength and toughness, are generally difficult to machine in conventional machining. Also tool wear is high in conventional machining processes. Wire Cut Electric Discharge (WEDM) machining is particularly used for machining complex profiles, demanding very high accuracy. The current work focuses on the optimization of roughness of a surface that is machined using WEDM; the process parameters considered for optimization are pulse-on-time (Pon), pulse-off time (Poff), wire feedrate (WFR) and spark gap voltage (SGV). One of the surface integrity aspect is considered as surface roughness (SR) and other related to machining output considered as material removal rate (MRR) for the output responses. The paper presents, a multi-criteria decision making technique, with Grey Relational Analysis (GRA) integrated with Particle Swarm Optimization (PSO) for optimizing the process parameters. Further, confirmation tests that were conducted also validated the improvement in SR and MRR.

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Wan, Yi, Zhan Qiang Liu, Hong Tao Zhu, and Xing Ai. "Research on Cutting Cast Super Alloy K24 with Milling and Abrasive Water Jet Methods." Materials Science Forum 697-698 (September 2011): 157–60. http://dx.doi.org/10.4028/www.scientific.net/msf.697-698.157.

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A difficult-to-machining material, cast supper alloy K24 has been cut with two different methods, milling and abrasive waterjet (AWJ). It is shown that milling is characterized by high tool cost, low efficiency, and good surface roughness while abrasive waterjet brings high efficiency and worse surface quality. The results have proven that the combination use of AWJ and milling is an efficient way in cutting K24.

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Kumar, Ramanuj, and Ashok Kumar Sahoo. "Pulsating minimum quantity lubrication assisted high speed turning on bio-medical Ti-6Al-4V ELI Alloy: An experimental investigation." Mechanics & Industry 21, no. 6 (2020): 625. http://dx.doi.org/10.1051/meca/2020097.

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Machining of bio-medical Ti-6Al-4V ELI grade is categorized in difficult to cut metal alloys due to its lower thermal conductivity and highly reactive in nature at elevated temperature. However, to improve the machinability of this alloy, controlling the temperature during cutting action is a challenging task. On this context, current work introduced a novel cooling strategy named as pulsating minimum quantity lubrication technique to investigate the surface roughness, surface texture (surface topology, surface profile, amplitude distribution curve, Bearing area curve, and Power spectrum), tool-work temperature, and flank wear in high-speed CNC turning of Ti-6Al-4V ELI Alloy. Feed is the leading influencing term towards surface roughness, pulse time contributing the highest impact towards tool-work temperature while flank wear is largely influenced by cutting speed. Abrasion, notch wear, adhesion and diffusion mode of wear is found.

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Zhai, Yuan Sheng, Shuai Qiao, Xian Li Liu, and Qiang Hu. "The Simulation Analysis and Experimental Research on the Process of PCBN Cutting Super-Alloy." Key Engineering Materials 589-590 (October 2013): 88–93. http://dx.doi.org/10.4028/www.scientific.net/kem.589-590.88.

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Ni-based super-alloy GH4169 that is most widely used in aerospace is one of the most difficult-to-cut materials, which can be machined by Polycrystalline Cubic Boron Nitride (PCBN) tool. In this paper, the cutting process of super-alloy GH4169 with PCBN tool is researched by simulation, combing with the comparison and verification of experiment. The change rules of cutting temperature and force under different cutting parameters are obtained in this study. The reasonable parameter ranges of high efficiency cutting are proposed in cutting parameter optimization, in order to provide a reference for high efficiency machining of super-alloy GH4169 with PCBN tool.

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Yamada, Shinji, Yukio Maeda, Tatsuo Motoyoshi, Hideaki Tanaka, Kazuya Kato, and Takanori Yazawa. "Tool Wear Characteristics of Cylindrical Cutting of Nickel-Based Super Alloy." Advanced Materials Research 1136 (January 2016): 168–72. http://dx.doi.org/10.4028/www.scientific.net/amr.1136.168.

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Recently, high-combustion-efficiency jet engines have become essential in the aircraft industry. High burning temperatures are necessary to maximize the combustion efficiency of jet engines. Inconel 718, which has excellent mechanical and chemical properties, has been selected for use in many jet engine parts. However, it is difficult to cut because of its low thermal conductivity. Consequently, wet cutting is typically used to reduce the heat generated in cutting Inconel 718. In this study, we conducted experiments to examine the relationships between the cutting characteristics and tool fracture in wet cutting.

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Kodama, Hiroyuki, Toshiki Hirogaki, Eiichi Aoyama, and Keiji Ogawa. "An Indicative End-Milling Condition Decision Support System Using Data-Mining for Difficult-to-Cut Materials Based on Comparison with Irregular Pitch and Lead End-Mill and General Purpose End-Mill." Advanced Materials Research 797 (September 2013): 177–82. http://dx.doi.org/10.4028/www.scientific.net/amr.797.177.

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Data-mining methods using hierarchical and non-hierarchical clustering are proposed that will help engineers determine appropriate end-milling conditions. We have constructed a system that uses clustering techniques and tool catalog data to support the determination of end-milling conditions for different types of difficult-to-cut materials such as austenitic stainless steel, Ni-base superalloy, and titanium alloy. Variable cluster analysis and the K-means method were used together to identify tool shape parameters that have a linear relationship with the end-milling conditions listed in the catalogs. The response surface method and significant tool shape parameters obtained by clustering were used to derive end-milling condition decision equations, which were used to determine the indicative end-milling conditions for each material. Comparison with the conditions recommended by toolmakers demonstrated that our proposed system can be used to determine the cutting speeds for various difficult-to-cut materials.

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