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Procedia CIRP 1 (2012) 226 231

5th CIRP Conference on High Performance Cutting 2012

High Performance Titanium Milling at Low Cutting Speed

Pavel Bacha*, George Trmalb, Pavel Zemana, Jiri Vanaa, Jan Malya
a
Research Centre for Manufacturing Technology, Czech Technical University in Prague, Horska 3, 128 00, Praha 2, The Czech Republic
b
UWE, Bristol, UK, retired
* Corresponding author. Tel.: +420 605 205 911; fax:+420 221 990 999. E-mail address: p.bach@rcmt.cvut.cz

Abstract

When machining titanium alloys the process stability limits increase very rapidly with reduced cutting speed. The stability rise is
stronger than the drop of the cutting speed and it results in growth of removal rate. The increase in removal rate results in savings of
machining costs. There is definite advantage in cutter geometry with irregular pitch for increasing the limit of stability. Use of PM
HSS tools at low speeds for milling titanium alloys can be the most economical option. The paper introduces the concept of load
intensity for assessing tool wear in milling.

2012 The
2012 Published byPublished
Authors. Elsevier BV. Selection
by Elsevier B.V.and/or peer-review
Selection under responsibility
and/or peer-review of Prof. Konrad
under responsibility Wegener
of Professor Konrad Wegener

Keywords: Titanium; Milling; Low speed; Stability; PM-HSS tool wear; Cost;

1. Introduction
Many researchers have investigated the high speed
option of titanium machining by carbide tools aiming to
improve removal rate by means of cutting speed
increase. Leigh et al. [1] and Ezugwu et al. [2] were
typical among them. It resulted in optimisation of most
cutting parameters and tool design features but failed to
produce a significant break-through. It is still difficult to
reduce the cost of machining by increasing cutting
speeds above 80-100 m/min.
2. Used parameters
The parameters: cutter diameter Dc [mm], number of
teeth t, feed per tooth ft [mm] and radial depth of cut ae
[mm] were kept constant. The spindle speed ns [rpm]
and therefor cutting speed vc [m/min] were varied.
Limiting axial depth of cut for stable cutting ap lim (or
DOC) [mm] was derived experimentally. These
parameters are shown in Fig. 1.

1.1. Objectives and strategy

An alternative method of rough milling titanium,

described in this paper can be called Low Speed
Machining (LSM). Some benefits of using LSM can be
found in earlier papers [4], and [7]. This paper continues
the investigation finding additional benefits due to
Fig. 1 Cutting conditions
increased dynamic stability of the process. It also
provides experimental evidence of beneficial use of PM
There are two derived parameters: the first, Material
(powder metallurgy) HSS tools. It provides theoretical
removal rate Q [cm3/min] is characteristic of
and experimental base for the proposed technology, and
productivity, the second, Specific removal rate (removal
a practical application of the technology on a suitable
rate per unit of axial depth of cut) Q [(cm3/min)/cm]
machined component.

2212-8271 2012 The Authors. Published by Elsevier B.V. Selection and/or peer-review under responsibility of Professor Konrad Wegener
http://dx.doi.org/10.1016/j.procir.2012.04.040
 Pavel Bach et al. / Procedia CIRP 1 (2012) 226 231 227

identifies the load of the cutting edge and together with stable axial depth of cut aplim as a function of spindle
cutting speed is characteristic of tool wear. speed. The theory, however, has not indicated the
increase of process stability at low cutting speeds. It has
Table 1. Used parameters been determined experimentally and it has been later
explained as the effect of frictional damping at the flanks
Symbol Description Unit
of cutter teeth, [5]. The high stability at low speeds
VBave Average of width of flank [m] needs stiff tool-spindle structure at the tool tip. The
wear
torque must be also sufficient to provide efficient
VBmax Maximum of width of flank [m] cutting.
wear
As stated in 2., the theoretical and experimental part
OCR Overall cost rate [Euro/hour] of the investigation used the following parameters:
Tmach Machining time [hour/litre] Dc=32 mm, vc= 20-50 m/min, ae=1 mm, ft=0.1-0.2 mm.
Tprod Production time [hour/litre]
T1 Time for removing [min]
1 liter of material
Ted Edge durability time [min]
Cprod Production cost [Euro]
Ctool Tool cost [Euro]
Ctool1 Tool cost per 1 liter [Euro]
Ctd Tool cost per duration [Euro]
Ctot Total cost [Euro
Nr Number of reconditionings [1]
Pt Price of new tool [Euro] Fig. 2: Measured stability limits at low cutting speeds
Pr Price of reconditioning [Euro]
Preg Price of regrinding [Euro] As can be seen in Fig. 2, the experimental results
show that there is definitely increase in stability at low
Prec Price of recoating [Euro]
speeds below 40 m/min. This is shown by the border line
between stable and unstable cutting. The increase is
3. Limiting factors more pronounced for cutters with irregular pitch, which
are designed to suppress chatter.
Roughing operations are limited by Dynamic stability Cutting performance can be measured by material
limit (above the limit there are heavy vibration and poor removal rate Q. It can be evaluated at the stability limit
surface finish). There is also an important Economic using the following formula:
limit of minimum cost indicating an optimum process.
The cost consists of machining cost (the cost of machine Q = a p ,lim ae f t t ns
and the operator) and the tool cost. The high machining (1)
rate reduces the machining cost but generally increases
the tool wear and therefore the tool cost. Only these Together with the cutting speed, it can be used to
limiting factors were considered. calculate the maximum achievable Q without chatter
occurring.
4. Dynamic stability Irregular pitch of cutter teeth reduces the onset of
chatter. For cutting speeds within the range 20 30
Performance of any rough machining operation is m/min, the chatter doesnt occur till relatively high
limited by the process instability, which can be values of the ap , Fig. 2. This increases achievable Q
characterized and limited by the axial depth of cut (aplim) despite of the cutting speed reduction. The possible Q
and depends on modal properties of the entire machine- values are significantly higher than the values achieved
tool structure and also on the cutting resistance of the by speeds above 40 m/min because of the higher axial
machining process. Above the limit of stability the depth of cut. Thus, the tools, especially these with
machine experiences heavy vibration (chatter) and the irregular pitch, can achieve rather high performance if
process cannot continue. The theory has been described used under low cutting speeds below 40 m/min.
among others by J. Tlusty and M. Polacek [3]. Special However, the increase in Q due to higher stability can
stability lobe-form diagram based on experimentally be only achieved if the component geometry allows the
obtained results can be constructed to find the highest utilization of the chatter limiting depth of cut. This
228 Pavel Bach et al. / Procedia CIRP 1 (2012) 226 231
would be possible in deep pocketing, when the cutter
ramps first to the full depth and then contours as
opposed to small increments in depth and creating
pockets layer by layer.
5. Tool wear
The tool wear was characterized by the width of a
wear scar on the flank of the cutting edge. The standard
VBmax of flank wear was used.
5.1. Load intensity as a measure of wear rate
In order to provide meaningful analysis of
experimental results achieved with high axial depth of
cut it is useful to introduce a concept of Edge load
intensity, which is proportional to Specific removal rate.
This concept is often used in grinding to compare the
results on operations with different width of cut but
seldom in milling. As can be seen in Fig. 3 the cutter
could be represented by a series of disks of unit
thickness. The load on each disk is represented by load
intensity, which is the load per unit length of the cutting
edge.
Load Q
Q = =
ap ap
(2)
The disks are loaded equally and therefore wear
equally. Their wear is equal to the wear of the whole
cutting edge. The higher is the load intensity, the higher
is the rate of wear. Therefore the wear rate could be
considered proportional to load intensity.
Fig. 3: Intensity of the removal rate (Q = Q/ap)
The life of a single edge is expressed by durability of
cutting edge. It is the time from the beginning of cutting
to the end of its useful life, when edge wear reaches the
preselected limit VBmax.
The investigation discussed in this paper was
concerned with milling titanium alloy Ti6Al4V by HSS
tools at low cutting speeds. The task was concerned with
the benefit of increased stability at low cutting speeds
between 20 and 50 m/min as well as differences in HSS
tools (regular and irregular pitch). All tested tools had
the same cutting geometry, they were made from
different sorts of HSS, had the same diameter (32 mm),
4 teeth and length 106 mm, all have been tested in two
versions with regular and irregular pitch.
5.2. Machining at low speeds and low intensity testing
wear of tools
Fig. 4 shows the experimental results achieved with
low speed and low intensity. Curve with lower removal
rate and with higher intensity shows significantly higher
wear then the curve with higher removal rate and lower
intensity.
Durability of the cutting edge in the both cases has
been estimated because it would be laborious and
expensive to prolong the test and reach the end of edge
life. The durability time already corresponds to 6 hours
of machining.
Fig. 4 The longer durability time as a result of low load intensity in
spite of higher removal rate (irregular pitch). Edge durability time
Ted=360 min.
The wear model is based on a simple assumption that
that the wear is proportional to the energy wasted in the
cutting process. The cutting edge durability time is
therefore inversely proportional to the product of
frictional force (proportional to Specific removal rate)
and cutting speed. The coefficient of proportionality
include the force and the effect of limiting wear and it is
obtained by comparing edge durability times of the
model and corresponding experimental results in Excel
program. In cost calculation of tool cost is low, so that
small inaccuracies in the simple wear model are not of
high importance.
The algorithm for cutting edge durability calculation
was as follows:
1
Ted = (3)
Coef vc Q
 Pavel Bach et al. / Procedia CIRP 1 (2012) 226 231
where Coef = 6.0E-5, vc = cutting speed, [m/min], Q
= intensity of removal rate, [cm2.min].
The algorithm was reasonably confirmed by the
results of tests for machining titanium by HSS cutters in
the required range of cutting speeds and intensity of
edge load.
5.3. Effect of regular and irregular pitch
The significant difference between wear of tools
designed with equal and unequal pitch is shown in
Fehler! Ungltiger Eigenverweis auf Textmarke.. The
wear of cutting edge of cutter with irregular pitch is
increasing more slowly. It is because the irregular pitch
of teeth makes the work of tool smoother, with lower
level of forced vibration. Consequently, the flank wear is
decreased.
As have been shown in Fig.2 the use of tool with
irregular pitch increases also the resistance to self-
excited vibration and consequently limit of stability. As
shown in Fehler! Ungltiger Eigenverweis auf
Textmarke. it is reflected in lower wear and increased
durability.
Fig. 5: Effect of regular and irregular pitch (20 m/min, low intensity Q
= 0.8 cm2/min)
6. Economy, cost of manufacturing
6.1. Production cost
Cost of using the machining depends on the cost of
the machining facilities as well as on the selected
machining conditions. In a basic model the cost of
facilities can be expressed by a single parameter called
OCR (Overall Cost Rate) in Euro/hour. It consists of
machine cost, labour cost and overheads. This is in fact
the cost of using the machine with an operator and
overheads added and it is quoted for an hour of use. The
tool cost is considered separately.
In an effort to generalize the findings and evaluate the
effect of removal rate, the cost of machining is related to
volume of removed material of 1000 cm3 (= 1 litre). The
production cost in Euro includes in addition the time
229
losses such as clamping, tool change, ramping etc. and it
can be calculated via equation (4). OCR was selected 58
Euro/hour. Production time (Tprod) can be expressed by
multiplication of machining time and Rp/m parameter, see
equation (5). Rp/m is ratio between production time and a
machining time (Tprod/Tmach). It was selected as 1.5.
Machining time is dependent only on removal rate, see
equation (6).
C prod = Tprod OCR
(4)
T prod = R p / m Tmac
(5)
1000
T m ach = [ hour / litre ] (6)
60 Q
Total cost of machining can be also expressed:
Ctot = C prod + Ctool (7)
As in any milling operation the cost can be calculated
as explained above. However, in the high stability region
the axial depth of cut can be increased as seen in Fig. 2
to the stability limit. This leads to significant increase in
removal rate and therefore a significant reduction in the
production cost for lower speeds.
6.2. Tool cost
Cost of tool can be calculated from the price of tool,
price of reconditioning (regrinding and recoating)
number of reconditioning in a life of tool and edge
durability time. It is calculated from following relations:
Pr N r
Ctd = Pt +
Nr + 1
T1 (8)
C tool ,1 = C td
Ted
(9)
Pr = Pre g + Pre c ,
(10)
where Pt=230 Euro (tool price), Preg=5 Euro (price of
regrinding), Prec=15 Euro (price of recoating), Nr=10
(number of reconditioning).
The tool cost was determined on the basis of the
formula and parameters ap and vc outlined in Fig. 2. The
calculation is based on the durability algorithm.
Results of total cost in Euro per litre (E/Litre) of
removed titanium and its components of tool cost and
production cost are shown in Fig. 6. As shown in the
figure, the cost in the high stability region (between 20
230 Pavel Bach et al. / Procedia CIRP 1 (2012) 226 231

and 30 m/min) is considerably lower than at higher

speeds. This is because the axial depth of cut ap
increases the removal rate, which reduces the production
cost. The tool cost is low because of low intensity of
edge load and does not significantly affect the total cost.
It forms rather a low percentage of it. This means that
any inaccuracies in the estimates of the tool cost could
not significantly affect the total cost.

Fig. 7 High limit of chatter at low cutting speed

The increased rate of material removal can be

therefore achieved only where this increase of axial
depth of cut is not prevented by technological reasons.
Fig. 6: Costs of machining in high stability region
However, the titanium made aerospace components are
often designed with deep pockets, which serve to
7. Example
remove material which carry low stress. Material in
these pockets can be usually removed with high axial
Expressing the savings in Euro per litre (1000 cm3) of
depth of the cutter.
removed material is not always the best way to appeal to
Undercarriages are usually manufactured from
practitioners in a machine shop. It was therefore decided
titanium. A typical component, which can be used to
to present a realistic example. This case is based on true
demonstrate the process and its benefits, can be seen in
industrial experience. The details are sufficiently
Fig. 8.
realistic to provide a convincing example.
It has been argued already that the phenomenon of
increased stability at low speeds can be utilized to
increase productivity on titanium, which is machined at
rather low speeds 30 to 80 m/min already. This has been
explained by Tlusty, [5] by additional process damping.
This allows an increase of axial depth of cut, which
provides a limit of chatter. It is shown in Fig. 7. At
reduced speed to just over 12 m/min the limit ap is
increased to 40 mm. The data for the graph can be
obtained by measurement of results of a tap test and by
using the results for calculation. The calculation also
uses an estimate of specific cutting resistance and is
often part of software in a specialized instrument
MetalMax provided by MLI, [6]). It could be also
determined experimentally by machining tests.
Fig. 8 Component and technology

The component could be a part of undercarriage of a

large civil aircraft, where it is used as a lever-beam to
join the bearings of the landing wheels. The
undercarriage incorporating the lever-beam can be seen
in Fig. 9 where the position of the lever beam is outlined
in white dotted line. The Fig. 8 also provides a
technological procedure. The first step, shown in detail
a) in the figure, shows machining a part of the outer
outline to the depth of 40 mm. The exact dimensions are
not known but the length of the lever beam has been
 Pavel Bach et al. / Procedia CIRP 1 (2012) 226 231
estimated as 2.5 m. Length of the outer contour is about
5000 mm, depth of the pocket 78 mm. Basic machining
parameters were selected as usually recommended
(cutter diameter 63 mm, 6 teeth, feed per tooth 0.5 mm,
ae=23 mm). Spindle speed originally 252 rpm was
reduced to 78 rpm, which increased the limiting axial
depth of cut from ap=3.9 mm to ap=40 mm. This is
shown in Fig. 7.
Fig. 9 A planes undercarriage employing the lever- beam
The more meaningful parameters like removal rate,
edge load intensity and feed per minute could be
determined by simple calculations.
Machining at a lower speed 78 rpm, has 3 times
slower feed rate but about 3 times high removal rate.
This is because higher edge length the cutting edge load
intensity is 3 times lower, this means very low wear. It
will therefore cut 3 times faster with 10 times longer tool
life. Clearly the LSM is much more efficient. Similar
situation applies in other features like pockets made on
reversed clamped components Fig. 8, b) c). It seems that
two to three components will be machined by LSM at 78
rpm (15.4 m/min) as compared with only one component
using conventional approach with spindle speed 252 rpm
(50 m/min).
Certain parts of the machined surface (bottom of the
pockets or clamping surface) must be made by face
milling without benefits of long edge. It is estimated that
the whole component can be machined with LSM in less
than 50% of time compared with the one machined with
HSM.
8. Discussion
This paper describes an investigation the use of PM
HSS tools and outlines possible economic benefits.
There is a high stability region at cutting speeds of 20 to
35 m/min. This high stability region allows high axial
depth of cut without chatter, which is normally a limiting
factor. In this region increasing the axial depth of cut
increases removal rate and reduces the machining cost
but does not increase the wear, which depends on
specific removal rate. Machining in the region of high
stability requires a rigid machine capable of sufficient
231
torque at low speeds. The technique can reach full
benefits only on suitable components allowing
machining with the axial depth of cut on or close to the
limit of stability.
It must be remembered that not all components can be
machined in this way, which would achieve full benefits
of this technique. But many could and analysing the
range of components manufactured in a company could
allow introduction of technological changes with
significant benefits.
The cost conditions differs from company to
company and what is good for one could not be the best
for another. Cost of testing titanium is high and just
turning it into chips for analysis is wasteful. Companies
can monitor technology they are using and, guided by
this analysis, arrive at optimum, the lowest cost of
production.
It is obvious that the role of research is not in
providing exact analysis of specific situation. The role of
research is in identification of new approaches, which
could allow a significant cost reduction. Each company
should monitor its production, not by introducing
transducers and assessing machine health, but monitor
the economic health of production by analysing the
production records.
The cutter running at lower speed allows the use of
high speed steel. The current HSS cutters are made by
powder metallurgy and have a very fine grain. They
keep a sharp cutting edge and dont suffer from
chipping. The tests have shown in [4] that they offer
very long life and their cost is low.
Acknowledgements
The research has been funded within the framework
of the grand 1M6840770003 of the Ministry of
Education and Youth of the Czech Republic.
References
[1] Leigh, EP., Schueler, JK., Tlusty J. Advanced Machining
Techniques on Titanium Rotor Parts, Proceedings of 56th Annual
Forum of AHS, Virginia Beach, 2000, p.119.
[2] Ezugwu, EO, Wang, ZM. Titanium Alloys and their Machinability
- a review, Journal of Materials Processing Technology, 1997, 68,
p. 262274.
[3] Tlusty, J, Polacek, M. The Stability of the Machine Tool Against
Self Excited Vibration in Machining, Prod. Eng. Res. Conf.
ASME, Pittsburgh, 1963, p. 1628.
[4] Trmal, GJ, Bach, P. Economy of Titanium Milling, MM Science
Journal, 2008, No. 10, p. 6570.
[5] Tlusty, J. Manufacturing Processes and Equipment, New Jersey,
Prentice Hall, 1999.
[6] Manufacturing Laboratories Inc., Las Vegas, Nevada, www.mfg-
labs.com.