Ti5553 Titanium Plate Material Processing Conditions for Aerospace and Medical Applications

Processing Ti5553 Titanium Plate material requires a reduction in cutting speed by approximately 50% under medium processing conditions. During slot milling, the reduction in speed is more significant, while it is less so during side milling. Large-scale machining necessitates the use of indexable inserts, especially when handling large workpieces or applications with high metal removal rates. In recent years, the development of indexable tools has closely paralleled that of solid carbide tools, with a primary focus on machining difficult-to-machine materials, including titanium alloys.

Indexable Tools for Titanium Alloys

Walter's signature product for machining difficult materials is the PVD aluminum oxide-coated Tiger.tec material (PVD-Tiger). Other materials like WSM35 with high wear-resistant coatings and WSP45 have also been introduced to the market. The G77 groove design, developed concurrently with PVD-Tiger, is also suitable for titanium alloy applications. This groove design features a 20-degree rake angle and a unique micro-groove, combining PVD coating, high-positive geometry, and special edge preparations.

Increased Demand in Aerospace and Medical Fields

Feedback from aircraft manufacturers indicates that the use of titanium alloy components has more than doubled. As the demand for titanium alloy workpieces increases, materials like Ti6Al4V and the emerging Ti5553 (Ti-5Al-5Mo-5V-3Cr) are becoming increasingly important. The unique properties of titanium alloys present significant challenges for cutting tools and their applications, especially in aerospace and medical industries, where components often have thin walls and complex shapes.

Factors Affecting Tool Life

Three factors severely impact tool life when machining titanium alloys: very low thermal conductivity (Ti6Al4V = 7.56 W/mK; steel Ck45 = 51.9 W/mK), relatively low modulus of elasticity (Ti6Al4V = 110 kN/mm²; steel Ck45 = 210 kN/mm²), and distinct rubber-like properties. Heat generated during cutting tends to concentrate at the cutting edge rather than being carried away by chips, requiring the use of cooling fluids. Lower material elasticity increases the tendency for vibration and built-up edge formation, necessitating a significant reduction in cutting speed.

Challenges with New Ti5553 Material

The emergence of new materials like Ti5553 exacerbates machining difficulties. Ti6Al4V is a balanced alpha-beta alloy with a microstructure that includes both hexagonal alpha and body-centered cubic beta phases. In contrast, Ti5553 is closer to a beta-phase alloy with higher resistance to heat and greater difficulty in machining, boasting a tensile strength of around 900 N/mm².

Walter's round tools development manager, Josef Giessler, emphasizes the need for optimized tool solutions for professional titanium alloy machining. Solid carbide tools are typically used for diameters around 20-25 mm to reduce vibration and built-up edge formation. Polished rake faces, AlCrN coatings, and internal cooling significantly improve machining quality and efficiency.

In a project with Airbus, the Ti40 tool doubled the machining life of a Ti6Al4V workpiece, achieving a maximum cutting volume of 80 cm³/min (Vc = 25 m/min). The new generation of solid carbide tools set a benchmark with cutting volumes of 160-200 cm³/min (Vc = 50-60 m/min) for a 25 mm diameter. Walter's experts further tested Ti5553 to determine how new-generation tools cope with more complex machining challenges, dealing with material tensile strength of 1400 N/mm² and Brinell hardness of 430.

Conclusion

As the demand for titanium alloy components grows in aerospace and medical applications, the challenges for cutting tools and machining techniques continue to evolve. The Ti5553 alloy, with its superior properties, requires advanced tool solutions to meet the stringent demands of high-performance and precision machining applications.

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