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1 Journal of Machine Engineering

1 2012

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Estimation tool for optimum cutting condition of difficult to cut materials

Soe Y. H., Tanabe I., Iyama T., Da Cruz J. R.

Journal of Machine Engineering

2012

Vol. 12, No. 1

76--88

Titanium alloy and nickel alloy are mainly used for several aeronautical parts due to their high strength and durability at high temperature. However, thermal conductivity of these materials are very low and most of the heat generated during cutting are concentrately conducted into the cutting tool. Therefore, the tool become extremely high temperature resulting shorter tool life. In this paper, a method for calculating the optimum cutting condition for cutting low thermal conductivity materials such as titanium alloy and nickel alloy is developed and evaluated. The temperatures on the cutting tool tip for various combination of tools and work piece materials were calculated by dynamic FEM simulation and the estimation tool for optimum cutting condition is created based on these results. The amount of heat flow and the temperature on the cutting tool were calculated based on cutting theory. Then, optimum cutting conditions for those materials were estimated by newly developed program. The method was finally evaluated by several experiments. It is concluded from the results that (1) The developed program is applicable for estimation of optimum cutting conditions regarding titanium alloy and nickel alloy. (2) Titanium alloy (Ti6Al4V) can be machined with longer tool life using estimated optimum cutting condition.