Micro-drilling of Ti–6Al–4V alloy: The effects of cooling/lubricating |
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| Affiliation: | 1. Department of Mechanical Engineering, Faculty of Technology, Afyon Kocatepe University, 03200 Afyonkarahisar, Turkey;2. Department of Mechanical Engineering, Faculty of Technology, Marmara University, Goztepe Campus, Kadikoy, 34722 Istanbul, Turkey;3. Department of Mechanical Engineering, Faculty of Engineering and Natural Sciences, Y?ld?r?m Beyaz?t University, Ankara, Turkey;1. School of Mechatronics Engineering, Harbin Institute of Technology, Harbin 150001, China;2. Machining and Condition Monitoring Group, Faculty of Engineering, University of Nottingham, NG7 2RD, UK;1. Department of Energy, Systems, Territory and Constructions Engineering, University of Pisa, Italy;2. Department of Industrial and Production Engineering, Shahjalal University of Science and Technology, Bangladesh;3. Department of Industrial Engineering, University of Parma, Italy;1. Indian Institute of Technology (ISM) Dhanbad, India;2. Indian Institute of Technology, Bombay,India;1. Indian Institute of Technology Patna, Patliputra Colony Patna-800013, Bihar, India;2. South Ural State University, 76, Lenin Avenue, Chelyabinsk, 454080, Russian Federation;1. Department of Mechanical Engineering, Faculty of Technology, Afyon Kocatepe University, 03200 Afyonkarahisar, Turkey;2. Department of Mechanical Engineering, Faculty of Engineering and Natural Sciences, Y?ld?r?m Beyaz?t University, Ankara, Turkey |
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| Abstract: | This paper presents a series of experimental investigations of the effects of various machining conditions dry, flooded, minimum quantity lubrication (MQL), and cryogenic] and cutting parameters (cutting speed and feed rate) on thrust force, torque, tool wear, burr formation, and surface roughness in micro-drilling of Ti–6Al–4V alloy. A set of uncoated carbide twist drills with a diameter of 700 μm were used for making holes in the workpiece material. Both machining conditions and cutting parameters were found to influence the thrust force and torque. The thrust force and torque are higher in cryogenic cooling. It was found that the MQL condition produced the highest engagement torque amplitude in comparison to the other coolant–lubrication conditions. The maximum average torque value was obtained in the dry drilling process. There was no substantial effect of various coolant–lubrication conditions on burr height. However, it was observed that the burr height was at a minimum level in cryogenic drilling. Increasing feed rate and decreasing spindle speed increased the entry and exit burr height. The minimum surface roughness values were obtained in the flood cooling condition. In the dry drilling process, increased cutting speed resulted in reduced hardness on the subsurface of the drilled hole. This indicates that the surface and subsurface of the drilled hole were subject to softening in the dry micro-drilling process. The softening at the subsurface of drilled holes under different cooling and lubrication conditions is much smaller compared to the dry micro-drilling process. |
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| Keywords: | Micro-drilling Ti–6Al–4V Minimum quantity lubrication Cryogenic cooling Surface integrity Surface roughness |
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