Topic of Research Seminar: Investigation into the machinability of advanced Aerospace Alloys (Ti-6Al-4V) under Ultrasonic Vibrations Assisted End-Milling (UVAEM)
Abstract: Titanium is the 9th most abundant element and also the 4th most abundant structural metal in the earth’s crust after aluminium, iron and magnesium. Titanium and its alloys offer a unique combination of features and mechanical properties like heat resistance, corrosion resistance, toughness, higher operating temperature, chemical inertness and higher strength to weight ratio. Due to these remarkably unique properties, these alloys are extensively utilized in major industrial setups where mechanical parts are usually used under severe climatic and operational conditions including biomedical, automotive, power generation, chemical, marine, oil, gas and aerospace applications. However, despite their superb properties, these alloys are categorized as difficult-to-cut materials with poor machinability characteristics because of their low thermal conductivity, elevated temperature strength, chemical reactivity, strain hardening ability and poor dislocation motion through the micro-structure. Major challenges in their machinability are high cutting temperatures, higher tool wear, high vibrations levels, low material removal rate (MRR) and poor surface integrity of the parts. Ti-6Al-4V is an alpha-beta (α + β) titanium alloy currently being regarded as a standard major industrial titanium alloy (50 % of titanium production). It also remained a focus of many modeling, experimental and evaluation studies in recent past to overcome its machinability challenges. Miniaturization in devices has forced a shift towards micro and meso-scale machining. Sustainability and green manufacturing concepts have shifted focus in machining from cutting fluids towards modern cooling approaches to minimize or eliminate them. In present research, cutting forces, tool wear, surface roughness and burr in Ultrasonic Vibrations Assisted End Milling of Ti–6Al–4V at meso-scale under Dry, Flooded, Minimum Quantity Lubrication & Cryogenic cooling have been analyzed to develop optimum machining parameters. Taguchi L16 orthogonal array was designed to perform experiments keeping Cutting Speed, Feed per tooth, Depth of cut, Ultrasonic vibrations amplitude & Cooling environment as inputs. ANOVA was used to analyze contribution ratios by these parameters towards cutting forces, tool wear, surface roughness and burr.
Subject field of Topic: Machining, Design & Manufacturing
Name of Speaker: Adil Rauf
Professional Rank of Speaker: PhD Student, DME/SMME
University Email of Speaker: [email protected]
Affiliation of Speaker: School of Mechanical and Manufacturing Engineering (SMME), NUST
Date and Venue: Friday, 28 Jun 2024 from 1100 hrs to 1130 hrs in SMME conference room, School of Mechanical and Manufacturing Engineering (SMME), NUST Islamabad