Abstract
M.Ing.
This report documents the steps taken to gain insight into the phenomena of high speed machining (HSM) of titanium alloys. This was done by firstly studying titanium alloys and the problems associated with machining titanium alloys. An experimental set-up and procedure was developed for measuring and recording both the machining temperature and component forces.
A sufficient set of experimental data was collected through extensive experimentation. The cutting temperatures and component forces in HSM of Ti-6Al-4V were examined simultaneously. The cutting speed was found to be the most influential and limiting parameter on the machining temperature and component forces. A new approach for modeling the temperatures in HSM of titanium alloys was developed. Analytical predictions of the cutting temperatures were performed and used to evaluate the influence of a variation in the process parameters on the cutting temperature. The research provides insight for future work into the phenomena of HSM of titanium alloys
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The results of the analytical model were found to be representative and comparable to the experimental data. It is however expected that the deviation between the predicted and measured result may be significantly reduced by changing the experimental approach. It is recommended that a complete set of experiments be done, using a new tool insert for every cut, thus removing the effect of possible tool wear on the experimental data obtained.
In addition it is recommended that the iterative solution be improved through more in depth programming, considering the change in both the thermal and mechanical materials properties with a change in temperature. Ultimately the assumptions made in order to simplify the problem addressed in this report needs to be improved upon, in order to analyze data trends and even magnitudes to a greater degree of certainty.