Prediction of Ti-6Al-4V Chip Morphology & Surface Characteristics from Machining Forces due to Adiabatic Shear Banding

Abstract

The research objective of this project is to measure and investigate the ultra-high frequency aspects of adiabatic shear banding (ASB) during the Ti-6Al-4V chip generation process through the use of a piezoelectric-based dynamometer and accelerometer-based multi directional force and acceleration sensing systems. For this, a coupled force-acceleration measurement system will be first assembled and calibrated. Then, an experimental design of machining tests will be conducted to elucidate the relationships between ASB-induced machining force/acceleration components and the resulting chip morphology and process characteristics. This understanding is expected to help generate strategies to control ASB geometry and characteristics by suitably altering the process parameters such as machining speed, feed and cutting depth. These will be validated through further machining tests to show productivity improvements.