Influence of tool material on forces, temperature, and surface quality of Ti-15333 alloy in CT and UAT

Abstract

Ultrasonically assisted turning (UAT) is a progressive machining method in which vibration is applied to the cutting insert in the direction of the cutting tool velocity to reduce the cutting forces, significantly and increase the surface finish noticeably. However, the key question about the tool damage caused by the vibration and its effect on the cutting forces, surface roughness and process zone temperature is still unknown in UAT. This paper presents experimental analysis of the effect of worn tool in UAT and conventional-turning (CT) of β-Ti-15V-3Al-3Cr-3Sn (Ti-15333) alloy on surface quality of a machined surface, temperature of the process zone and cutting forces using KC5510 (PVD TiAlN) and CP500 (PVD (Ti,Al)N-TiN) cutting inserts. In UAT, the tool edge damages in CP500 inserts increased with tested machining time resulted a growth of 8 N and 10 N in tangential force component in CT and UAT, respectively. Similarly, with the progression of tool edge damage, a growth of 1.7% and 9.3% in process zone temperature was observed in CT and UAT, respectively. The surface roughness results revealed a gradual degradation with machining time, however, the results UAT with a worn tool was significantly better when compared to CT, with a virgin tool.