Abstract:
Machining is a basically method of material removal (in the form of chips) due to the shear deformation, with sharp cutting tools. In order to achieve high productivity, comprehensive research has been carried out on machinability of different materials. Titanium alloy Ti6Al4V (Grade 5) is widely used in many engineering fields due to its attractive specific strength and corrosion resistance. However, titanium alloys often produce serrated chips which leads key machinability challenges (tool life, cutting forces, energy consumption-SCE, surface quality) relative to other materials (except at low speed). Chip morphology parameters such as shear angle and chip thickness ratio are essential aspects for estimating cutting forces and energy consumed. Energy consumed at the tool’s tip for the removal of unit volume of the material is associated with the mechanics of a cutting process which leads production quality and production cost. Therefore, it is very important to understand the mechanism of chips formation and chip morphology parameters in high-speed cutting.
The fundamental research contribution in this thesis is to analyze and compare shear angle and chip formation of titanium alloy Ti6Al4V for selected set of cutting speed and feed rate under dry and cryogenic cutting environment for better understanding of machinability. Shear angle is state parameter of chip morphology to estimate the cutting forces and energy consumption, (higher the shear angle, lower will be the energy consumption and cutting forces), that why research was focused on shear angle analysis.
