Abstract: Artificial neural networks (ANN) are used in distinct researching fields and professions, and are prepared by cooperation of scientists in different fields such as computer engineering, electronic, structure, biology and so many different branches of science. Many models are built correlating the parameters and the outputs in electrical discharge machining (EDM) concern for different types of materials. Up till now model for Ti-5Al-2.5Sn alloy in the case of electrical discharge machining performance characteristics has not been developed. Therefore, in the present work, it is attempted to generate a model of material removal rate (MRR) for Ti-5Al-2.5Sn material by means of Artificial Neural Network. The experimentation is performed according to the design of experiment (DOE) of response surface methodology (RSM). To generate the DOE four parameters such as peak current, pulse on time, pulse off time and servo voltage and one output as MRR are considered. Ti-5Al-2.5Sn alloy is machined with positive polarity of copper electrode. Finally the developed model is tested with confirmation test. The confirmation test yields an error as within the agreeable limit. To investigate the effect of the parameters on performance sensitivity analysis is also carried out which reveals that the peak current having more effect on EDM performance.
Abstract: Shear spinning is closely related to the asymmetric incremental sheet forming (AISF) that could significantly reduce costs incurred by the fabrication of complex aeronautical components with a minimal environmental impact. The spinning experiments were carried out on commercially pure titanium (Ti-Gr2) and Ti-6Al-4V (Ti-Gr5) alloy. Three forming modes were used to characterize the titanium alloys properties from the point of view of different spinning parameters. The structure and properties of the materials were assessed by means of metallographic analyses and microhardness measurements. The highest value wall angle failure limit was achieved using spinning parameters mode for both materials. The feed rate effect was observed only in the samples from the Ti-Gr2 material, when a refinement of the grain microstructure with lower feed rate and higher tangential speed occurred. Ti-Gr5 alloy exhibited a decrease of the microhardness at higher straining due to recovery processes.
Abstract: Electrical discharge machining (EDM) is a relatively modern machining process having distinct advantages over other machining processes and can machine Ti-alloys effectively. The present study emphasizes the features of the development of regression equation based on response surface methodology (RSM) for correlating the interactive and higher-order influences of machining parameters on surface finish of Titanium alloy Ti-6Al-4V. The process parameters selected in this study are discharge current, pulse on time, pulse off time and servo voltage. Machining has been accomplished using negative polarity of Graphite electrode. Analysis of variance is employed to ascertain the adequacy of the developed regression model. Experiments based on central composite of response surface method are carried out. Scanning electron microscopy (SEM) analysis was performed to investigate the surface topography of the EDMed job. The results evidence that the proposed regression equation can predict the surface roughness effectively. The lower ampere and short pulse on time yield better surface finish.
Abstract: Titanium alloys like Ti-6Al-2Sn-4Zr-6Mo (Ti-
6246) are widely used in aerospace applications. Component
manufacturing, however, is difficult and expensive as their
machinability is extremely poor. A thorough understanding of the
chip formation process is needed to improve related metal cutting
operations.In the current study, orthogonal cutting experiments have
been performed and theresulting chips were analyzed by optical
microscopy and scanning electron microscopy.Chips from aTi-
6246ingot were produced at different cutting speeds and cutting
depths. During the experiments, depending of the cutting conditions,
continuous or segmented chips were formed. Narrow, highly
deformed and grain oriented zones, the so-called shear zone,
separated individual segments. Different material properties have
been measured in the shear zones and the segments.
Abstract: Ti-6Al-4V alloy has demonstrated a high strength to
weight ratio as well as good properties at high temperature. The
successful application of the alloy in some important areas depends
on suitable joining techniques. Friction welding has many
advantageous features to be chosen for joining Titanium alloys. The
present work investigates the feasibility of producing similar metal
joints of this Titanium alloy by rotary friction welding method. The
joints are produced at three different speeds and the performances of
the welded joints are evaluated by conducting microstructure studies,
Vickers Hardness and tensile tests at the joints. It is found that the
weld joints produced are sound and the ductile fractures in the tensile
weld specimens occur at locations away from the welded joints. It is
also found that a rotational speed of 1500 RPM can produce a very
good weld, with other parameters kept constant.
Abstract: Greenhouse gases (GHG) emissions impose major
threat to global warming potential (GWP). Unfortunately
manufacturing sector is one of the major sources that contribute
towards the rapid increase in greenhouse gases (GHG) emissions. In
manufacturing sector electric power consumption is the major driver
that influences CO2 emission. Titanium alloys are widely utilized in
aerospace, automotive and petrochemical sectors because of their
high strength to weight ratio and corrosion resistance. Titanium
alloys are termed as difficult to cut materials because of their poor
machinability rating. The present study analyzes energy consumption
during cutting with reference to material removal rate (MRR).
Surface roughness was also measured in order to optimize energy
consumption.
Abstract: In present work, prediction the effect of nose radius, rz (mm) on the equivalent strain (PEEQ) and surface finish during the machining of titanium alloy (Ti-6Al-4V) through orthogonal cutting process. The results were performed at several of the nose radiuses, rz (mm) while the cutting speed, vc (m/min), feed rate, f (mm/tooth) and depth of cut, d (mm) were remained constant. The equivalent plastic strain (PEEQ) was estimated by using finite element modeling (FEM) and applied through ABAQUS/EXPLICIT software. The simulation results led to conclude that the equivalent plastic strain (PEEQ) was increased and surface roughness (Ra) decreased when increasing nose radius, rz (mm) during the machining of titanium alloy (Ti–6Al–4V) in dry cutting conditions.
Abstract: Laser beam forming is a novel technique developed for the joining of metallic components. In this study, an overview of the laser beam forming process, areas of application, the basic mechanisms of the laser beam forming process, some recent research
studies and the need to focus more research effort on improving the
laser-material interaction of laser beam forming of titanium and its
alloys are presented.
Abstract: This paper deals optimized model to investigate the
effects of peak current, pulse on time and pulse off time in EDM performance on material removal rate of titanium alloy utilizing copper tungsten as electrode and positive polarity of the electrode. The experiments are carried out on Ti6Al4V. Experiments were
conducted by varying the peak current, pulse on time and pulse off time. A mathematical model is developed to correlate the influences of these variables and material removal rate of workpiece. Design of
experiments (DOE) method and response surface methodology
(RSM) techniques are implemented. The validity test of the fit and adequacy of the proposed models has been carried out through
analysis of variance (ANOVA). The obtained results evidence that as
the material removal rate increases as peak current and pulse on time
increases. The effect of pulse off time on MRR changes with peak ampere. The optimum machining conditions in favor of material removal rate are verified and compared. The optimum machining
conditions in favor of material removal rate are estimated and verified with proposed optimized results. It is observed that the developed model is within the limits of the agreeable error (about
4%) when compared to experimental results. This result leads to desirable material removal rate and economical industrial machining to optimize the input parameters.
Abstract: Titanium alloys like the modern alloy Ti 6Al 2Sn 4Zr 6Mo (Ti-6246) combine excellent specific mechanical properties and corrosion resistance. On the other hand,due to their material characteristics, machining of these alloys is difficult to perform. The aim of the current study is the analyses of wear mechanisms of coated cemented carbide tools applied in orthogonal cutting experiments of Ti-6246 alloy. Round bars were machined with standard coated tools in dry conditions on a CNC latheusing a wide range of cutting speeds and cutting depths. Tool wear mechanisms were afterwards investigated by means of stereo microscopy, optical microscopy, confocal microscopy and scanning electron microscopy. Wear mechanisms included fracture of the tool tip (total failure) and abrasion. Specific wear features like crater wear, micro cracks and built-up edgeformation appeared depending of the mechanical and thermal conditions generated in the workpiece surface by the cutting action.
Abstract: This paper reports the fatigue crack growth behaviour
of gas tungsten arc, electron beam and laser beam welded Ti-6Al-4V
titanium alloy. Centre cracked tensile specimens were prepared to
evaluate the fatigue crack growth behaviour. A 100kN servo
hydraulic controlled fatigue testing machine was used under constant
amplitude uniaxial tensile load (stress ratio of 0.1 and frequency of
10 Hz). Crack growth curves were plotted and crack growth
parameters (exponent and intercept) were evaluated. Critical and
threshold stress intensity factor ranges were also evaluated. Fatigue
crack growth behaviour of welds was correlated with mechanical
properties and microstructural characteristics of welds. Of the three
joints, the joint fabricated by laser beam welding exhibited higher
fatigue crack growth resistance due to the presence of fine lamellar
microstructure in the weld metal.
Abstract: The study of effect of laser scanning speed on
material efficiency in Ti6Al4V application is very important because unspent powder is not reusable because of high temperature oxygen
pick-up and contamination. This study carried out an extensive study
on the effect of scanning speed on material efficiency by varying the
speed between 0.01 to 0.1m/sec. The samples are wire brushed and
cleaned with acetone after each deposition to remove un-melted
particles from the surface of the deposit. The substrate is weighed before and after deposition. A formula was developed to calculate the
material efficiency and the scanning speed was compared with the
powder efficiency obtained. The results are presented and discussed.
The study revealed that the optimum scanning speed exists for this study at 0.01m/sec, above and below which the powder efficiency
will drop
Abstract: In this paper the combination of thermal oxidation and
electrochemical anodizing processes is used to produce titanium
oxide layers. The response of titanium alloy Ti6Al4V to oxidation
processes at various temperatures and electrochemical anodizing in
various voltages are investigated. Scanning electron microscopy
(SEM); X-Ray Diffraction (XRD) and porosity determination have
been used to characterize the oxide layer thickness, surface
morphology, oxide layer-substrate adhesion and porosity. In the first
experiment, samples modified by thermal oxidation process then
followed by electrochemical anodizing. Second experiment consists
of surfaces modified by electrochemical anodizing process and then
followed by thermal oxidation. The first method shows better
properties than other one. In second experiment, Surfaces modified
were achieved by thicker and more adherent thick oxide layers on
titanium surface. The existence of an electrochemical anodized oxide
layer did not improve the adhesion of thermal oxide layer. The high
temperature, thermal formation of an oxide layer leads to a coarse
oxide grain morphology and a complete oxidative particle. In
addition, in high temperature oxidation porosity content is increased.
The oxide layer of thermal oxidation and electrochemical anodizing
processes; on Ti–6Al–4V substrate was covered with different
colored oxide layers.
Abstract: In this paper, a methodology of a model based on
predicting the tool forces oblique machining are introduced by
adopting the orthogonal technique. The applied analytical calculation
is mostly based on Devries model and some parts of the methodology
are employed from Amareggo-Brown model. Model validation is
performed by comparing experimental data with the prediction results
on machining titanium alloy (Ti-6Al-4V) based on micro-cutting tool
perspective. Good agreements with the experiments are observed. A
detailed friction form that affected the tool forces also been examined
with reasonable results obtained.