Modeling the Surface Roughness for Machining Titanium Alloy TC4 with Taper Ball-end Cutter
Large composite fan blades of high-performance commercial aero-engines are at risk of delamination and gluing during high-speed rotation.It is necessary to protect the leading edge of the blade by assembling a titanium alloy TC4 leading edge metal reinforcement edge through the gluing process.However,the performance of gluing is greatly affected by the roughness of the assembled surface.In this paper,for the machining surface roughness of the inner cavity of titanium alloy TC4 leading edge metal reinforcement edge,with spindle speed,feed per tooth and axial cutting depth as design factors,four experiments were conducted using slender tapered ball-end cutters to machine the titanium alloy TC4.The surface roughness of the machined samples was measured.Based on the collected data,empirical surface roughness models were established for the four types of slender tapered ball-end cutters.The results show that the spindle speed increases and the surface roughness decreases considerably at a diameter of 5.0mm.Conversely,the surface roughness increases for a diameter of 3.0mm.The surface roughness machined by the tapered ball end cutter with diameters of 4.0mm and 2.4mm did not change significantly when the spindle speed and feed per tooth increased.The surface roughness machined by all the four diameters of the cutters increased substantially with increase in axial depth of cut.
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