High Speed Turning

of
Titanium (Ti-6Al-4V) Alloy

Anil Srivastava, Ph.D.

Manager, Manufacturing Technology
TechSolve, Inc., Cincinnati, OH 45237
 Outline
• Applications of Titanium Alloys

• Technical Difficulties in Machining Titanium Alloys

• High Speed Turning of Ti-6Al-4V Alloy

• Some Recent Test Results

• Conclusions

2
 Application of Titanium Alloys
• Titanium and its alloys are today used in:
– Aerospace
– Medical device
– Food and chemical industries
• Titanium alloys offers:
– High strength-to-weight ratio
– Super corrosion resistance
– Bio-compatibility
• Titanium alloys are difficult-to-machine due to:
– Low thermal conductivity and diffusivity
– High rigidity and low elasticity modulus
– High chemical reactivity at elevated temperatures
– Work hardening characteristics

3
 Machining Titanium for Economical Production
BASIC RULES
• Use low cutting speeds – a change from 6 to 46 meters per min (20 to
150 sfpm) with carbide tools results in a temperature change from
427°C to 927°C (800°F to 1700°F).

• Use high feed rates – a change from 0.05 to 0.51 mm/rev (0.002 to
0.020 in/rev) results in a temperature increase of only 149°C (300°F).

• Use generous amounts of cutting fluid – coolant carries away heat,

washes away chips, and reduces cutting forces.

• Use sharp tools – replace them at the first sign of wear, or as

determined by production/cost considerations. Complete tool failure
occurs rather quickly after small initial amount of wear takes place.

• Never stop feeding – while a tool and a workpiece are in moving

contact. Permitting a tool to dwell in moving contact causes work
hardening and promotes smearing, galling, seizing, and total tool
breakdown.
4
(Courtesy of Supra Alloys, Inc.)
 Recent News

• Lockheed Martin has obtained government approval to use

‘cryogenic’ titanium machining process in production of the F-35
Lightning II stealth fighter that will improve tool-life by a factor of 10
with appropriate material removal processing speed.

• The Joint Program Office in coordination with the F-35 Fracture

Control Board (FCB) approved the new process for standard
roughing operations, impacting the most time-consuming and cost-
intensive machining processes associated with manufacturing
titanium parts.

• Broadly applied, this new technology could improve affordability and

efficiency in the production of the F-35, which is approximately 25%
titanium by weight.
American Manufacturing, September, 2011

5
 Effect of Cutting Speed and Feed on Tool-Life

Table: Typical parameters for turning

Ti-6Al-4V gas turbine components
CUTTING DEPTH OF
TOOL FEED
OPERATION SPEED CUT
MATERIAL (in/rev)
(SFPM) (in)
Turn (Rough) C-2 150 0.010 0.250
Turn (Finish) C-2 200 0.006 - 0.008 0.010 - 0.030
Turn (Finish) C-2 300 0.006 - 0.008 0.010 - 0.030
(Courtesy of Supra Alloys, Inc.)

Figure: Effect of cutting speed and feed on

tool-life when turning Ti-6Al-4V

6
 Issues with Increasing Productivity and Possibilities

• In the past, improvement in cutting-tool performance by the

application of coating technology has been very frustrating.
However, developments of interest include specially designed
turning tools such as micro-edge geometry and new coatings.

• There seems to be great potential in machining of titanium with C-2

carbides when designed with proper geometry.

• Also, very little improvement in productivity has been experienced

by exploring new combinations of machining parameters.

• Data is needed to determine the speeds at which reproducible and

reliable tool life of the order of 5 to 10 min can be obtained, and to
determine whether these conditions improve the economics of
titanium machining.

7
High Speed Turning of
Titanium (Ti-6Al-4V) Alloy
 Turning Test Conditions
• Work Material : Titanium (Ti-6Al-4V) Alloy Bar (2 in diameter)
• Tool Holder : Type CTGPL 164
• Cutting Tool : Uncoated/Coated/Micro-edge/Super-finished
Edge Geometry Carbide Inserts (TPG 432;
Grade – K313)
• Types of Coatings : TiAlN, [C8, C15, C2-SL Nano-Layers], and
[#2390, #2391, #2393, #2414 Ultra-hard]
• Cutting Speeds : 327 (100), 393 (120), 656 (200), 787 (240)
SFPM(m/min)
• Feed Rates : 0.002 (0.050), 0.003 (0.075), 0.004 (0.100),
0.005 (0.125) IPR (mm/rev.)
• Depth of Cut : 0.040 (1.000) in (mm)
• Cutting Fluid : few tests without coolant and few with flooded
coolant application (Trim Sol – 5% vol.)

9
 Turning of Titanium (Ti-6Al-4V) Alloy

Experimental Set-up for Turning Tests

10
 Types of Nano-layered and Ultra-hard Coatings
Nano-layered Coatings:

1. C-8: TiAlSiCN based coating

2. C-15: CrAlSiN-CrAlSiYN based

coating

3. C2-SL: TiAlN-CrN based coating

(All the three are PVD coatings)

Ultra-hard Coatings:

1. #2390: Multi-layer CrAlN coating

2. #2391: Multi-layer TiAlN coating Figure: High Magnification XTEM Bright Field
Image of C2-SL Superlattice Coating.

3. #2393/#2414: HfB2 coating

(1 & 2 PVD; 3 is PVD+CVD coating)

11
 Turning Test Results
Average Cutting Force (N)
1800
Uncoated Cutting Speed - 240 m/min
1600 C8 - Nanolayer Coated
C15 - Nanolayer Coated
1400
C2-SL - Nanolayer Coated
1200 2390 Ultrahard Coated
2391 Ultrahard Coated
1000
2393 Ultrahard Coated

800 Variable Edge Prep

600

400

200

0
0.025 0.05 0.075 0.1 0.125 0.15

Feed Rate (mm/rev)

Figure: Effect of Feed Rate on Average Cutting Force

12
 Turning Test Results
1400
Uncoated Cutting Speed - 200 m/min
C8 - Nanolayer Coated
1200

Average Cutting Force (N)

C15 - Nanolayer Coated
C2-SL - Nanolayer Coated
1000
2390 Ultrahard Coated
2391 Ultrahard Coated
800
2393 Ultrahard Coated
Variable Edge Prep
600

400

200

0
0.025 0.05 0.075 0.1 0.125 0.15

Feed Rate (mm/rev)

350
Cutting Speed - 120 m/min
300
Average Cutting Force (N)

250

200

150

100 Uncoated C8 - Nanolayer Coated

C15 - Nanolayer Coated C2-SL - Nanolayer Coated
50 2390 Ultrahard Coated 2391 Ultrahard Coated
2393 Ultrahard Coated Variable Edge Prep
0
0.025 0.05 0.075 0.1 0.125 0.15

Feed Rate (mm/rev)

Figure: Effect of Feed Rate on Average Cutting Force

13
 Turning Test Results
1400
Uncoated
C8 - Nanolayer Coated
Feed Rate - 0.125 mm/rev
1200 C15 - Nanolayer Coated

Average Cutting Force (N)

C2-SL - Nanolayer Coated
1000 2390 Ultrahard Coated
2391 Ultrahard Coated
800 2393 Ultrahard Coated
Variable Edge Prep
600

400

200

0
100 120 140 160 180 200 220 240

Cutting Speed (m/min)

1800
Uncoated
1600 C8 - Nanolayer Coated Feed Rate - 0.100 mm/rev
Average Cutting Force (N)

C15 - Nanolayer Coated

1400 C2-SL - Nanolayer Coated
2390 Ultrahard Coated
1200
2391 Ultrahard Coated
1000 2393 Ultrahard Coated
Variable Edge Prep
800
600
400
200
0
100 120 140 160 180 200 220 240

Cutting Speed (m/min)

Figure: Effect of Cutting Speed on Average Cutting Force

14
 Turning Test Results
1600
Feed Rate - 0.075 mm/rev
1400
Uncoated

Average Cutting Force (N)

1200 C8 - Nanolayer Coated
C15 - Nanolayer Coated
1000 C2-SL - Nanolayer Coated
2390 Ultrahard Coated
2391 Ultrahard Coated
800
2393 Ultrahard Coated
Variable Edge Prep
600

400

200

0
100 120 140 160 180 200 220 240

Cutting Speed (m/min)

250
Feed Rate - 0.050 mm/rev
Average Cutting Force (N)

200

150

Uncoated
100 C8 - Nanolayer Coated
C15 - Nanolayer Coated
C2-SL - Nanolayer Coated
2390 Ultrahard Coated
50 2391 Ultrahard Coated
2393 Ultrahard Coated
Variable Edge Prep
0
100 120 140 160 180 200 220 240

Cutting Speed (m/min)

Figure: Effect of Cutting Speed on Average Cutting Force

15
 Turning Test Results

Uncoated C-8 Nano-layered # 2390 Ultrahard

C-15 Nano-layered #2393 Ultrahard

Cutting Speed: 240 m/min,

Feed Rate: 0.100 mm/rev,
Depth of Cut: 1.000 mm

Figure: Tool Wear during Machining of Titanium (Ti-6Al-4V) Alloy

16
 Turning Test Results

Uncoated C-8 Nano-layered # 2390 Ultrahard Uncoated C-8 Nano-layered # 2390 Ultrahard

C-15 Nano-layered C2-SL Nano-layered #2391 Ultrahard C-15 Nano-layered C2-SL Nano-layered #2391 Ultrahard

#2393 Ultrahard Variable Edge Prep #2393 Ultrahard Variable Edge Prep
Cutting Speed : 240 m/min, Cutting Speed: 240 m/min,
Feed Rate : 0.075 mm/rev, Feed Rate: 0.050 mm/rev,
Depth of Cut : 1.000 mm Depth of Cut: 1.000 mm

Figure: Tool Wear during Machining of Titanium (Ti-6Al-4V) Alloy

17
 Turning Test Results

Uncoated C-8 Nano-layered # 2390 Ultrahard

Uncoated C-8 Nanolayered C-15 Nanolayered

C-15 Nano-layered C2-SL Nano-layered #2391 Ultrahard

# 2390 Ultrahard #2391 Ultrahard #2393 Ultrahard

#2393 Ultrahard

Cutting Speed: 200 m/min, Cutting Speed: 200 m/min,

Feed Rate: 0.125 mm/rev, Feed Rate: 0.100 mm/rev,
Depth of Cut: 1.000 mm Depth of Cut: 1.000 mm

Figure: Tool Wear during Machining of Titanium (Ti-6Al-4V) Alloy

18
 Turning Test Results

Uncoated C-8 Nano-layered # 2390 Ultrahard Uncoated C-8 Nano-layered # 2390 Ultrahard

C-15 Nano-layered C2-SL Nano-layered #2391 Ultrahard C-15 Nano-layered C2-SL Nano-layered #2391 Ultrahard

#2393 Ultrahard Variable Edge Prep #2393 Ultrahard Variable Edge Prep

Cutting Speed: 200 m/min, Cutting Speed: 200 m/min,

Feed Rate: 0.075 mm/rev, Feed Rate: 0.050 mm/rev,
Depth of Cut: 1.000 mm Depth of Cut: 1.000 mm

Figure: Tool Wear during Machining of Titanium (Ti-6Al-4V) Alloy

19
 Turning Test Results

Uncoated C-8 Nano-layered # 2390 Ultrahard Uncoated C-8 Nano-layered # 2390 Ultrahard

C-15 Nanolayered C2-SL Nanolayered #2391 Ultrahard C-15 Nano-layered C2-SL Nano-layered #2391 Ultrahard

#2393 Ultrahard Variable Edge Prep #2393 Ultrahard Variable Edge Prep

Cutting Speed: 120 m/min, Cutting Speed: 120 m/min,

Feed Rate: 0.125 mm/rev, Feed Rate: 0.100 mm/rev,
Depth of Cut: 1.000 mm Depth of Cut: 1.000 mm

Figure: Tool Wear during Machining of Titanium (Ti-6Al-4V) Alloy

20
 Turning Test Results

Uncoated C-8 Nanolayered # 2390 Ultrahard Uncoated C-8 Nanolayered # 2390 Ultrahard

C-15 Nanolayered C2-SL Nanolayered #2391 Ultrahard

C-15 Nano-layered C2-SL Nano-layered #2391 Ultrahard

#2393 Ultrahard Variable Edge Prep #2393 Ultrahard Variable Edge Prep

Cutting Speed: 120 m/min, Cutting Speed: 120 m/min,

Feed Rate: 0.075 mm/rev, Feed Rate: 0.050 mm/rev,
Depth of Cut: 1.000 mm Depth of Cut: 1.00 mm)

Figure: Tool Wear during Machining of Titanium (Ti-6Al-4V) Alloy

21
 The Micro Machining Process (MMP)

Figure: The Micro Machining Process (MMP) and Cutting Tool Super Finishing.

The lowest frequency range is the "Form" of the part, and this is what
the designer sees on his CAD screen and is what he is ultimately trying to
manufacture. Layered on top of the Form is the "Waviness", which is
caused by the clearances built into the cutting machine that allow it to move
freely. Layered on top of the Waviness is the "Primary Micro Roughness",
which is normally attributed to the movement of the cutting tool as it
removes material, and is usually similar in shape to the cutting tool
geometry. Finally, layered on top of the Primary Micro Roughness is the
"Secondary Micro Roughness", which results from the roughness on the
surface of the cutting tool that was imparted on it during its manufacturing
process and is now being transferred to the part being cut.

22
 Friction at the Tool-Work-Chip Interface

Figure: Effect of Feed Rate on the Coefficient of Friction

(with/without coolant application)

23
 Turning Test Results

Cutting Speed: 100 m/min,

Feed-Rate: 0.075 mm/rev,
Depth of Cut: 1.000 mm,
Coolant: (5% vol.) Trim Sol

Figure: Maximum Tool-Wear v/s Machining Time

24
 Turning Test Results
0.6
Uncoated (K313) Coated C-8 Coated C-15
Coated C2-SL Superfinish Coated C-16
Ultrahard #2390 Ultrahard #2391 Ultrahard 2414 (2393)
0.5
Maximum Tool Wear (mm)

Uncoated (K313)
Coated C-16
0.4 Coated C- 8
Ultrahard # 2391

0.3
Ultra-hard # 2414 (2393)
Coated C2 -SL

0.2 Coated C-15

Ultrahard # 2390
0.1
Super-finished Cutting Edge

0
0 5 10 15 20 25 30 35 40 45 50

Cutting Time (min)

Cutting Speed - 120 m/min;

Feed Rate - 0.075 mm/rev;
Depth of Cut - 1.000 mm,
Cutting Fluid - Trim Sol (5% vol.)

Figure: Maximum Tool -Wear v/s Machining Time

25
 Magnetic Field Assisted Super-Finishing

Figure: Magnetic Field Assisted Super-Finishing of Carbide Insert

(Courtesy of University of Florida, Gainesville, FL)

26
 Edges of Carbide Inserts Super-Finished

27
 Insert Surface-Finish Measurement

28
 Polished Surface Roughness

29
 Some Recent Turning Test Results

30
 Conclusions and Future Work

• Several oblique (3-D) turning tests have been conducted using

uncoated, coated, cutting edge having micro-edge geometry, and
super-finished cutting edge carbide inserts.

• It seems that a few coatings may prove to be a good candidate

for machining of Titanium alloys.

• Super-finished cutting edge inserts show enhanced (~2X) tool life

in comparison to other uncoated and coated inserts.

• Further experiments are being conducted using super-finished

edged cutting tools with the goal of optimizing the level of super-
finishing that will provide maximum enhancement in tool-life and
productivity while turning Ti-6Al-4V Titanium alloy.

31
 Acknowledgment

• TechSolve wishes to thank Professor Hitomi,

University of Florida, Gainesville, FL; MicroTek
& UES, Inc., OH; Richter Precision Inc. &
Conicity Technologies, PA for providing ultra-
hard, nano-layered coated, special micro-edge
and super-finished cutting edge prep inserts
used for this study.

• Special thanks to National Science Foundation

(NSF) for supporting this research under the
Award No. 0757954.

32
Thank You !