The investigation and design of a focused high pressure cooling technique for the milling of Ti6Al4V

Hammond, D. R. ; Koen, D. ; Oosthuizen, G. A. (2011-09)

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Conference of the ISEM 2011 Proceedings, Stellenbosch, South Africa, 21 - 23 September 2011.

Conference theme - Innovative Systems Thinking: Unravelling Complexity for Successful Solutions.

Conference Paper

Titanium is used in aircrafts structures and engines. The materials’ low thermal conductivity and chip segmentation during machining cause a fluctuating heat load on the cutting edge. The extreme reactivity of titanium at elevated temperatures and its adhesive phenomena gives it the characteristic of being difficult-to- machine. The reduction of the chip contact length on the cutting tool edge will help to reduce the friction and thereby slow down tool wear. Various lubrication and cooling strategies were explored and evaluated in order to develop a new cooling technique that will be able to reduce the chip contact length. This will help to improve tool life and the surface integrity of the machined components. The tool wear was measured with an optical microscope in order to realize the performance of the different strategies. It was found that the high pressure cooling strategy showed to perform superior to the other strategies. Improved chip removal and reduced chip contact length with the cutting edge were found. Thereby, a new focused high pressure cooling cutting tool could be designed. The steps to design a cutting tool are shown and commented on. It is concluded that the high pressure cooling techniques show promising results and that future work is necessary to explore these benefits.

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