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Modeling of TiAl6V4 machining operations

: Klocke, F.; Markworth, L.; Messner, G.

Stevenson, R. ; International Institution for Production Engineering Research -CIRP-, Paris:
5th CIRP International Workshop on Modeling of Machining Operations 2002. Proceedings
Lexington, KY: Univ. of Kentucky, Center for Robotics and Manufacturing, 2002
ISBN: 0-9666706-1-2
International Workshop on Modeling of Machining Operations <5, 2002, Lexington/Ky.>
Conference Paper
Fraunhofer IPT ()
modeling; machining; FE simulation

The high cost of manufacture led the aerospace industry to look for high performance machining techniques for difficult-to-cut materials like titanium alloys. Although considerable progress was obtained in the past regarding the machining rate, the results remain behind expectations. The poor cutting performance is mainly caused by the low thermal conductivity and extremely high thermal stability of these materials. This paper summarizes various research activities at Fraunhofer IPT and WZL RWTH Aachen which have been performed in order to develop and apply a modeling approach for TiAl6V4 machining operations. Based on FE-simulations and experimental analogy cutting tests, investigations on the influence and significance of cutting parameter were carried out. The gained results have been transferred to the simultaneous 5-axis milling process and have been used for manufacturing TiAl6V4 engine blades. This paper focuses on this development while special interest is pointed to the systematic analysis of the correlation between machining parameter and surface integrity properties including the verification of theoretical approaches and FE-simulation.