The objective of this paper is to assess the correlation of volumetric tool wear (VTW) and wear rate of carbide tools on the material removal rate (MRR) of titanium alloys. A previously developed methodology for assessing the worn tool material volume is utilized for quantifying the VTW of carbide tools when machining Ti–6Al–4V. To capture the tool response, controlled milling experiments are conducted at suitable corner points of the recommended feed-speed design space, for constant stock material removal volumes. For each case, the tool material volume worn away, as well as the corresponding volumetric wear profile evolution in terms of a set of geometric coefficients, is quantified—these are then related to the MRR. Further, the volumetric wear rate and the M-ratio (volume of stock removed to VTW) which is a measure of the cutting tool efficiency, are related to the MRR—these provide a tool-life based optimal MRR for profitability. This work not only elevates tool wear from a 1D to 3D concept, but helps in assessing machining economics from a stock material-removal-efficiency perspective as well.
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April 2015
Research-Article
Correlation of the Volumetric Tool Wear Rate of Carbide Milling Inserts With the Material Removal Rate of Ti–6Al–4V
Mathew Kuttolamadom,
Mathew Kuttolamadom
Manufacturing & Mechanical Engg. Technology,
e-mail: mathew@tamu.edu
Texas A&M University
,College Station, TX 77843
e-mail: mathew@tamu.edu
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Laine Mears,
Laine Mears
International Center for Automotive Research,
e-mail: mears@clemson.edu
Clemson University
,Greenville, SC 29607
e-mail: mears@clemson.edu
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Thomas Kurfess
Thomas Kurfess
Dept. of Mechanical Engg.,
e-mail: kurfess@gatech.edu
Georgia Institute of Technology
,Atlanta, GA 30332
e-mail: kurfess@gatech.edu
Search for other works by this author on:
Mathew Kuttolamadom
Manufacturing & Mechanical Engg. Technology,
e-mail: mathew@tamu.edu
Texas A&M University
,College Station, TX 77843
e-mail: mathew@tamu.edu
Parikshit Mehta
Laine Mears
International Center for Automotive Research,
e-mail: mears@clemson.edu
Clemson University
,Greenville, SC 29607
e-mail: mears@clemson.edu
Thomas Kurfess
Dept. of Mechanical Engg.,
e-mail: kurfess@gatech.edu
Georgia Institute of Technology
,Atlanta, GA 30332
e-mail: kurfess@gatech.edu
Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received February 28, 2014; final manuscript received January 9, 2015; published online February 16, 2015. Assoc. Editor: Patrick Kwon.
J. Manuf. Sci. Eng. Apr 2015, 137(2): 021021 (8 pages)
Published Online: April 1, 2015
Article history
Received:
February 28, 2014
Revision Received:
January 9, 2015
Online:
February 16, 2015
Citation
Kuttolamadom, M., Mehta, P., Mears, L., and Kurfess, T. (April 1, 2015). "Correlation of the Volumetric Tool Wear Rate of Carbide Milling Inserts With the Material Removal Rate of Ti–6Al–4V." ASME. J. Manuf. Sci. Eng. April 2015; 137(2): 021021. https://doi.org/10.1115/1.4029649
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