Titanium and nickel alloys represent a significant metal portion of the aircraft structural and engine components. When these critical structural components in aerospace industry are manufactured with the objective to reach high reliability levels, surface integrity is one of the most relevant parameters used for evaluating the quality of finish machined surfaces. The residual stresses and surface alteration (white etch layer and depth of work hardening) induced by machining of titanium alloys and nickel-based alloys are very critical due to safety and sustainability concerns. This review paper provides an overview of machining induced surface integrity in titanium and nickel alloys. There are many different types of surface integrity problems reported in literature, and among these, residual stresses, white layer and work hardening layers, as well as microstructural alterations can be studied in order to improve surface qualities of end products. Many parameters affect the surface quality of workpieces, and cutting speed, feed rate, depth of cut, tool geometry and preparation, tool wear, and workpiece properties are among the most important ones worth to investigate. Experimental and empirical studies as well as analytical and Finite Element modeling based approaches are offered in order to better understand machining induced surface integrity. In the current state-of-the-art however, a comprehensive and systematic modeling approach based on the process physics and applicable to the industrial processes is still missing. It is concluded that further modeling studies are needed to create predictive physics-based models that is in good agreement with reliable experiments, while explaining the effects of many parameters, for machining of titanium alloys and nickel-based alloys.

Machining induced surface integrity in titanium and nickel alloys: A review

Machining difficult-to-machine materials such as alloys used in aerospace, nuclear and medical industries are usually accompanied with low productivity, poor surface quality and short tool life. Despite the broad use of the term difficult-to-machine or hard-to-cut materials, the area of these types of materials and their properties are not clear yet. On the other hand, using cutting fluids is a common technique for improving machinability and has been acknowledged since early 20th. However, the environmental and health hazards associated with the use of conventional cutting fluids together with developing governmental regulations have resulted in increasing machining costs. The aim of this paper is to review and identify the materials known as difficult-to-machine and their properties. In addition, different cutting fluids are reviewed and major health and environmental concerns about their usage in material cutting industries are defined. Finally, advances in reducing and/or eliminating the use of conventional cutting fluids are reviewed and discussed.

/pdf/environmentally-conscious-machining-of-difficult-to-machine-32ov2j8z58.pdf

Environmentally conscious machining of difficult-to-machine materials with regard to cutting fluids

Recent advances in modelling of metal machining processes

This paper presents an overview of the recent advances in high performance cutting of aerospace alloys and composite currently used in aeroengine and aerostructure applications. Progress in cutting tool development and its effect on tool wear and surface integrity characteristics of difficult to machine materials such as nickel based alloys, titanium and composites is presented. Further, advances in cutting technologies are discussed, focusing on the role of hybrid machining processes and cooling strategies (MQL, high pressure coolant, cryogenic) on machining performance. Finally, industrial perspectives are provided in the context of machining specific components where future challenges are discussed.

High performance cutting of advanced aerospace alloys and composite materials

• The state-of-art of lightweight materials for automobiles is reviewed. • Representative materials are introduced with potential automotive applications, particularly on electric vehicles. • Given the recent advances in manufacturing, modeling, and characterization, both pros and cons of materials are summarized. • Solutions for future challenges are highlighted by developing advanced materials and/or improving the manufacturing. The growing challenges on fuel economy improvement and greenhouse gas emission control have become the driving force for automakers to produce lightweight automobiles. Also, the weight reduction may contribute to superior recyclability and/or vehicle performance ( e.g ., improved driving economy, braking behaviors, and crashworthiness). One effective strategy is to develop and implement lightweight yet high-performance materials as alternative solutions for conventional automotive materials such as cast iron and steel. Herein, a systematic review of available lightweight materials to produce next-generation automobiles is provided, including light alloys, high-strength steels, composites, and advanced materials in the ongoing research. By investigating the entire life cycle of automotive materials, physical/mechanical properties, characterization, manufacturing techniques, and potential applications of specific lightweight materials are discussed. Both the advantages and drawbacks of the reviewed materials are summarized, yielding the appropriate application scenarios for different lightweight materials. Given the future challenges, on expectations, the development of versatile advanced materials or improvement of the manufacturing/treatment techniques can be rather promising to resolve the possible bottlenecks and, in turn, enables more capable, safer, durable, and environmental-friendly vehicles. 

Advanced Lightweight Materials for Automobiles: A review

Titanium alloys have been widely used in the aerospace, biomedical and automotive industries because of their good strength-to-weight ratio and superior corrosion resistance. However, it is very difficult to machine them due to their poor machinability. When machining titanium alloys with conventional tools, the tool wear rate progresses rapidly, and it is generally difficult to achieve a cutting speed of over 60m/min. Other types of tool materials, including ceramic, diamond, and cubic boron nitride (CBN), are highly reactive with titanium alloys at higher temperature. However, binder-less CBN (BCBN) tools, which do not have any binder, sintering agent or catalyst, have a remarkably longer tool life than conventional CBN inserts even at high cutting speeds. In order to get deeper understanding of high speed machining (HSM) of titanium alloys, the generation of mathematical models is essential. The models are also needed to predict the machining parameters for HSM. This paper aims to give an overview of recent developments in machining and HSM of titanium alloys, geometrical modeling of HSM, and cutting force models for HSM of titanium alloys.

/pdf/a-review-on-high-speed-machining-of-titanium-alloys-48m4fcphhh.pdf

A Review on High-Speed Machining of Titanium Alloys ∗

The performance of conventional tools is poor when used to machine titanium alloys. In this paper, a new tool material, which is binderless cubic boron nitride (BCBN), is used for high-speed milling of a widely used titanium alloy Ti–6Al–4V. The performance and the wear mechanism of the BCBN tool have been investigated when slot milling the titanium alloy in terms of cutting forces, tool life and wear mechanism. This type of tool manifests longer tool life at high cutting speeds. Observations based on the SEM and EDX suggest that adhesion of workpiece and attrition are the main wear mechanisms of the BCBN tool when used in high-speed milling of Ti–6Al–4V.

High-speed milling of titanium alloys using binderless CBN tools

Tool wear characteristics of binderless CBN tools used in high-speed milling of titanium alloys

This paper presents an approach to select the optimal machining parameters for multi-pass milling. It is based on two recent approaches, genetic algorithm (GA) and simulated annealing (SA), which have been applied to many difficult combinatorial optimization problems with certain strengths and weaknesses. In this paper, a hybrid of GA and SA (GSA) is presented to use the strengths of GA and SA and overcome their weaknesses. In order to improve, the performance of GSA further, the parallel genetic simulated annealing (PGSA) has been developed and used to optimize the cutting parameters for multi-pass milling process. For comparison, conventional parallel GA (PGA) is also chosen as another optimization method. An application example that has been solved previously using the geometric programming (GP) and dynamic programming (DP) method is presented. From the given results, PGSA is shown to be more suitable and efficient for optimizing the cutting parameters for milling operation than GP+DP and PGA.

Optimization of multi-pass milling using parallel genetic algorithm and parallel genetic simulated annealing

The selection of optimal machining parameters plays an important part in computer-aided manufacturing. The optimisation of machining parameters is still the subject of many studies. Genetic algorithm (GA) and simulated annealing (SA) have been applied to many difficult combinatorial optimisation problems with certain strengths and weaknesses. In this paper, genetic simulated annealing (GSA), which is a hybrid of GA and SA, is used to determine optimal machining parameters for milling operations. For comparison, basic GA is also chosen as another optimisation method. An application example that has previously been solved using geometric programming (GP) method is presented. The results indicate that GSA is more efficient than GA and GP in the application of optimisation.

Optimisation of multi-pass milling using genetic algorithm and genetic simulated annealing

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