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Machining of titanium alloys with ultra-hard cutting tool materials

Pretorius, Cornelius Johannes (2013)
Ph.D. thesis, University of Birmingham.

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This research explores the relative merits of existing and novel ultra-hard tool materials for finish turning titanium alloys. Phase 1 of the experimental work comprised evaluating the machinability of Ti-6Al-2Sn-4Zr-6Mo when employing carbide tooling with respect to tool life, wear behaviour, workpiece surface integrity and cutting forces. The machinability of Ti-6Al-2Sn-4Zr-6Mo using PCBN tooling was evaluated in Phase 2 experiments. It was shown that even with the use of high pressure jet cooling, carbide and low content PCBN grade inserts were unsuitable for high-speed (~200 m/min) finish turning of titanium alloys. Phase 3 research evaluated the machinability of Ti-6Al-2Sn-4Zr-6Mo and Ti-6Al-4V when employing PCD tooling with respect to tool life, wear behaviour, workpiece surface integrity and cutting forces. Benchmark tests producing response surface models were developed using conventional low pressure fluid supply and were found to be suitable for the prediction of tool life, surface roughness and cutting force within the range of parameters studied. The PCD inserts significantly outperformed both carbide (by a factor > 24) and PCBN (by a factor > 12) tools in high-speed finish turning, although the performance varied depending on the PCD structure, edge geometry, period of engagement, undeformed chip thickness and jet fluid parameters.

Type of Work:Ph.D. thesis.
Supervisor(s):Aspinwall, David K. and Soo, Sein Leung
School/Faculty:Colleges (2008 onwards) > College of Engineering & Physical Sciences
Department:School of Mechanical Engineering
Additional Information:

Embargo until 31 July 2017

Subjects:TJ Mechanical engineering and machinery
TN Mining engineering. Metallurgy
Institution:University of Birmingham
ID Code:4385
This unpublished thesis/dissertation is copyright of the author and/or third parties. The intellectual property rights of the author or third parties in respect of this work are as defined by The Copyright Designs and Patents Act 1988 or as modified by any successor legislation. Any use made of information contained in this thesis/dissertation must be in accordance with that legislation and must be properly acknowledged. Further distribution or reproduction in any format is prohibited without the permission of the copyright holder.
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