Model Development for Cutting Optimization in High-Performance Titanium Machining

Titanium alloys have been widely used in the aerospace, biomedical and petroleum industries due to their good strength-to-weight ratio and superior corrosion resistance. Critical applications requiring optimal weight-optimized designs and resistance to extreme environmental conditions are ideal for the use of titanium. As designers look to further improve their designs and as modeling technologies advance, industries are turning to titanium more often than ever.

The benefits of using titanium come at a price, however. Where aluminum can be cut at rotational speeds exceeding 30,000 rpm with high feed rates and significant depth of cut, the inherent strength of titanium alloys causes increased cutting forces and poor machinability. The material’s low thermal conductivity creates elevated cutting temperatures concentrated at the tool/chip interface. Coupled with the fact that titanium has high chemical reactivity at elevated temperatures, what results is significant tool wear and cutting speeds on an order of magnitude lower than other structural metals.

This white paper discusses optimal cutting temperatures for titanium machining, and it explains how to manage thermal conditions for the highest levels of productivity and tool life. It discusses cutting stability and identifying the ideal machining parameters for achieving high metal-removal rates, all while maximizing tool life.

Approaches to modeling and testing of titanium machining processes are revealed, assisting manufacturers in obtaining maximum productivity, long tool life and excellent surface quality.

This white paper aims to help answer the following questions:

  • How can I optimize my titanium machining processes?
  • What causes rapid tool wear when machining titanium?
  • What are the best cutting parameters for titanium milling?
  • How can I increase tool life when machining titanium?
  • What speed should be used when milling titanium?
  • How can I increase metal-removal rates in titanium without costly tool wear?
  • What is the best temperature for titanium machining?
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