In Perm, methods to enhance the speed and quality of processing new titanium alloys have been discovered.

Titanium-based alloys are widely used in the aerospace industry. This material is known for its high strength, but it requires labor-intensive processing. During cutting, its surface tends to deform, leading to increased roughness, altered microstructure, and significant wear on the cutting tools. Currently, researchers are exploring alloys with ultra-fine grain structures to produce more advanced components. The cutting process for these alloys differs from that of standard coarse-grained materials, necessitating precise parameter selection. Scientists at Perm Polytechnic have identified the factors that ensure the desired quality of titanium products. Their findings enhance the material processing speed and reduce tool wear.

2024-12-03 10:02:03https://naked-science.ru/article/column/skorost-i-kachestvo-obrab

The article was published in the journal "High-Tech Technologies in Machine Engineering." The research was conducted as part of the strategic academic leadership program "Priority 2030."

The structure of most metals consists of crystals (grains) of various geometric shapes that can be examined under a microscope. In ultrafine-grained alloys, their size is less than one micrometer. Compared to "standard" coarse-grained materials, they exhibit higher fatigue resistance and are stronger, harder, and more wear-resistant.

The quality of the final surface of a part and the wear of the cutting tool depend on the selected modes and conditions for machining titanium alloys. The development of new high-quality materials may address issues related to their machinability. However, the effects of their increased strength and hardness on the machining process are still not sufficiently studied.

Scientists from Perm Polytechnic have conducted comprehensive studies and identified the most rational machining parameters for titanium with ultrafine-grained structure, which enable achieving the required surface quality of the product.

The researchers examined how cutting parameters such as speed, depth, and feed affect roughness, residual stresses, microhardness, and microstructure of the surface layer with both conventional coarse-grained and ultrafine-grained structures. Experiments with samples were conducted using eight different modes, revealing the most optimal conditions for better machining of the new type of titanium.

"The results showed that the lowest roughness is achieved at higher cutting speeds, whereas for the coarse-grained alloy, such a regime is not suitable, and the speed should be lower. This factor can increase the productivity of titanium machining by 1.5 times. The influence of feed and depth of cut is minimal," says Mikhail Pesin, Dean of the Mechanical Engineering Faculty at PNIPU, Doctor of Technical Sciences.

The researchers note that the application of any mode does not lead to damage to the layer. The microstructure of the alloy remains uniform and shows no signs of overheating. This indicates the feasibility of defect-free application of increased speeds.

"It has also been observed that when machining titanium alloy with an ultrafine-grained structure, vibrations, noise, and cutting power decrease by 15-20 percent compared to machining coarse-grained materials," adds Mikhail Pesin.

Scientists from Perm Polytechnic have proven the potential for using new titanium alloys in modern gas turbine units PD14 and PD35. They have better machinability than those currently used for aircraft engine components. The cutting modes recommended in the study will increase the speed of their mechanical processing and significantly reduce the wear of the cutting tool.