IJAT Vol.16 No.5 pp. 520-527
doi: 10.20965/ijat.2022.p0520


High-Efficiency Machining of Titanium Alloy Using Combined Machining Method of Driven Rotary Tool and Hale Machining

Yuto Yamazaki*, Tetsuo Takada**, Hideharu Kato*,†, and Shigehiko Sakamoto*

*Kanazawa Institute of Technology
7-1 Ohgigaoka, Nonoichi, Ishikawa 921-8501, Japan

Corresponding author

**Nakamura-Tome Precision Industry Co., Ltd., Hakusan, Japan

February 24, 2022
May 9, 2022
September 5, 2022
high-efficiency machining, titanium alloy, driven rotary tool, hale machining, MQL

Titanium alloys are widely used as aerospace materials, especially for turbine blades, due to their excellent mechanical properties. In the high-efficiency machining of titanium alloy turbine blades, the feed rate for ball-end milling is limited to 1000 mm/min due to the low thermal conductivity and chemical reactivity of the titanium alloy. These characteristics result in tool damage and an increase in the cutting temperature, significantly reducing the machined surface accuracy. A new processing method is thus needed for achieving a high accuracy and high efficiency in titanium alloy machining. It has been reported that driven rotary machining of hardened steel improves the machined surface and increases the processing efficiency, suggesting that high-efficiency machining can be realized by employing hale machining with a rotary tool. In this study, hale machining was performed using a driven rotary tool and the effects of different cutting conditions and cutting environment on the machining characteristics were investigated. The results showed that the tool life was longest at a feed rate of 9000 mm/min among the three feed conditions because the number of times of adhesion and detachment decreased with the decreasing friction distance of the cutting edge. Furthermore, it was clarified that adhesion formation at the cutting edge was suppressed by lubrication with an oil mist in a minimum quantity lubrication environment. This lubrication effect reduced the tool damage and adherence at the cutting edge, significantly extending the tool life and improving the machined surface quality compared to the results obtained in a wet environment.

Cite this article as:
Y. Yamazaki, T. Takada, H. Kato, and S. Sakamoto, “High-Efficiency Machining of Titanium Alloy Using Combined Machining Method of Driven Rotary Tool and Hale Machining,” Int. J. Automation Technol., Vol.16 No.5, pp. 520-527, 2022.
Data files:
  1. [1] C. Tan, F. Weng, S. Sui, Y. Chew, and G. Bi, “Progress and perspectives in laser additive manufacturing of key aeroengine materials,” Int. J. of Machine Tools and Manufacture, Vol.170, 103804, doi: 10.1016/j.ijmachtools.2021.103804, 2021.
  2. [2] S. Miller, “Advanced materials mean advanced engines,” Interdisciplinary Science Reviews, Vol.21, No.2, pp. 117-119, doi: 10.1179/isr.1996.21.2.117, 1996.
  3. [3] A. P. Mouritz, “Introduction to Aerospace Materials,” Elsevier, 2012.
  4. [4] K. Handa, “Aircraft Manufacturing Engineering,” Office HANS, 2006 (in Japanese).
  5. [5] D. Blanco, E. M. Rubio, R. M. Lorente-Pedreille, and M. A. Sáenz-Nuño, “Lightweight Structural Materials in Open Access: Latest Trends,” Materials, Vol.14, No.21, 6577, doi: 10.3390/ma 14216577, 2021.
  6. [6] E. O. Ezugwu, “Key improvements in the machining of difficult-to-cut aerospace superalloys,” Int. J. of Machine Tools and Manufacture, Vol.45, Nos.12-13, pp. 1353-1367, doi: 10.1016/j.ijmachtools.2005.02.003, 2005.
  7. [7] T. H. C. Childs, K. Maekawa, T. Obikawa, and Y. Yamane, “Metal machining theory and applications,” Butterworth-Heinemann, 2000.
  8. [8] L. Zhang, “Precision Machining of Advanced Materials,” Trans Tech Publications, 2001.
  9. [9] Toray Research Center, Inc., “Aircraft Technology, TRC R and D library,” Toray Research Center, Inc., pp. 292-296, 2014 (in Japanese).
  10. [10] H. Usuki, N. Narutaki, and Y. Yamane, “A study on turing of Ti-3Al-8V-6Cr-4Mo-4Zr,” J. of the Japan Society for Precision Engineering, Vol.61, No.7, pp. 1001-1005, doi: 10.2493/jjspe.61.1001, 1995 (in Japanese).
  11. [11] K. Shinozaki, A. Ikuta, H. Masuda, Y. Yamane, H. Kuroki, M. Aritoshi, and Y. Fukaya, “Fundamental Study on Adhesion Mechanism of Difficult-to-Machine Materials during Cutting (1st Report) – Estimation on Properties of Adhering Titanium Alloys to Cemented Carbide tool –,” J. of JSPE, Vol.66, No.2, pp. 224-228, doi: 10.2493/jjspe.66.224, 2000 (in Japanese).
  12. [12] P. J. Arrazola, A. Garay, L. M. Iriarte, M. Armendia, S. Marya, and F. L. Maître, “Machinability of titanium alloys (Ti6Al4V and Ti555.3),” J. of Materials Processing Technology, Vol.209, No.5, pp. 2223-2230, doi: 10.1016/j.jmatprotec.2008.06.020, 2009.
  13. [13] W. Ahmed, H. Hegab, H. A. Kishawy, and A. Mohany, “Estimation of temperature in machining with self-propelled rotary tools using finite element method,” J. of Manufacturing Processes, Vol.61, pp. 100-110, doi: 10.1016/j.jmapro.2020.10.080, 2021.
  14. [14] H. A. Kishawy, C. E. Becze, and D. G. McIntosh, “Tool performance and attainable surface quality during the machining of aerospace alloys using self-propelled rotary tools,” J. of Materials Processing Technology, Vol.152, No.3, pp. 266-271, doi: 10.1016/j.jmatprotec.2003.11.011, 2004.
  15. [15] H. A. Kishawy and J. Wilcox, “Tool wear and chip formation during hard turning with self-propelled rotary tool,” Int. J. of Machine Tools and Manufacture, Vol.43, No.4, pp. 433-439, doi: 10.1016/S0890-6955(02)00239-0, 2003.
  16. [16] P. Chen, “Cutting Temperature and Forces in Machining of High-Performance Materials with Self-Propelled Rotary tool,” JSME Int. J. Ser. 3, Vibration, Control Engineering, Engineering for Industry, Vol.35, No.1, pp. 180-185, doi: 10.1299/jsmec1988.35.180, 1992.
  17. [17] V. Dessoly, S. N. Melkote, and C. Lescalier, “Modeling and verification of cutting tool temperatures in rotary tool turning of hardened steel,” Int. J. of Machine Tools and Manufacture, Vol.44, No.4, pp. 1463-1470, doi: 10.1016/S08906955-(02)00239-0, 2004.
  18. [18] P. Chen and T. Hoshi, “Development of Self-propelled Rotary Tools Based on Cutting Characteristics,” J. of JSPE, Vol.60, No.9, pp. 1258-1262, doi: 10.2493/jjspe.60.1258, 1994.
  19. [19] J. Kossakowska and K. Jemielniak, “Application of Self-Propelled Rotary Tools for turning of difficult-to machine materials,” Procedia CIRP, Vol.1, pp. 425-430, doi: 10.1016/j.procir.2012.04.076, 2012.
  20. [20] H. Yamamoto, K. Satake, H. Sasahara, T. Narita, M. Tsutsumi, and T. Muraki, “Effect of MQL in High Efficiency Machining of Difficult-to-Materils by Driven Rotary Cutting – Tool Surface Temperatures and Chip Adhesions –,” J. of JSPE, Vol.77, No.3, pp. 316-321, doi: 10.2493/ jjspe.77.316, 2011 (in Japanese).
  21. [21] H. Kato et al., “Study on high efficiency finish turning of carburized hardened steel with driven-type rotary cutting,” Int. J. Automation Technol., Vol.7, No.3, pp. 321-328, 2013.
  22. [22] Y. Takeuchi, M. Yokoyama, T, Hisaki, H. Suzuki, and M. Sato, “6-Axis Control Finidhing of Workpiece with Sculptured Surface” J. of JSPE, Vol.60, No.12, pp. 1786-1790, 1994 (in Japanese).

*This site is desgined based on HTML5 and CSS3 for modern browsers, e.g. Chrome, Firefox, Safari, Edge, Opera.

Last updated on Jul. 23, 2024