Modelling On Metallurgical, Tribological and Sustainability Aspects in Energy-Efficient Machining of New Metastable Beta Titanium Alloy for Aircraft Engine Components Application

Description

The concerns for energy demand, machining efficiency, cost and sustainable production are increasing in the field of aerospace sector. The sensitive issues such as depleting fossil fuel sources, increasing pollution, and adverse climate changes have also drawn the focus of research towards the sustainable manufacturing. Therefore, the present proposal deals with the modelling of machining application of one such aerospace material i.e., New Metastable Beta Titanium Alloy by considering the social, economic and environmental effects. The machining tests will be performed under dry, wet, minimum quantity lubrication, liquid nitrogen and dry ice cooling conditions. The various metallurgical, tribological and sustainable aspects will be covered with this proposed proposal. This research work is aligned with the European Aerospace sector to optimize the energy in manufacturing and machining of different products. The ideology presented herein is the optimal model to manufacture the sustainable precise parts. The research work will provide a reference guide to perform the sustainable machining of aerospace grade titanium alloys considering the manufacturing constraints and energy optimization. This research will be highly beneficial for manufacturing experts, computational design engineers, and researchers involved in the area of machining mechanics and precise parts manufacturing. Research results will be theoretical background for scientists working in technologically advanced industries.

Summary of project results

The project aimed to address several issues and challenges related to the energy-efficient machining of a new metastable beta titanium alloy for aircraft engine components application. The potential issues or challenges that the project may have focused on are discussed below:

• The new metastable beta titanium alloy might possess unique metallurgical properties that can pose challenges during machining. Understanding and modeling these characteristics are crucial for optimizing the machining process.
• Tribological aspects refer to the study of friction, wear, and lubrication in materials. The alloy''s tribological behavior during machining could be complex, impacting tool wear, surface finish, and overall machining efficiency. Addressing these challenges is essential for prolonging tool life and improving the quality of machined surfaces.
• The project likely aimed to enhance the energy efficiency of the machining process. This involves optimizing cutting parameters, tool geometry, and machining strategies to reduce energy consumption while maintaining or improving machining performance.
• Sustainable machining involves minimizing the environmental impact of the machining process. This may include reducing waste generation, optimizing resource utilization, and selecting environmentally friendly cutting fluids. The project may have sought to model and incorporate sustainability aspects into the machining of the titanium alloy.
• Meeting the stringent requirements for aircraft engine components, such as precision, reliability, and safety, is crucial. The project likely addressed challenges related to achieving the required specifications for these components while using the new titanium alloy.
• The project likely involved the integration of advanced modeling techniques to simulate and predict the metallurgical, tribological, and sustainability aspects of the machining process. This integration is crucial for understanding the complex interactions and optimizing the overall machining performance.

The following activities were performed during the entire duration of project:

• We have conducted a detailed analysis of the metallurgical properties of the new metastable beta titanium alloy. This likely involved studying the alloy''s microstructure, hardness, and other relevant characteristics to understand its behavior during machining.
• Tribological properties were investigated during machining, focusing on friction, wear, and lubrication. This analysis would contribute to the development of strategies to minimize tool wear and improve the overall efficiency of the machining process.
• We have explored and developed machining strategies aimed at optimizing energy efficiency. This could involve experimenting with different cutting parameters, tool geometries, and cooling methods to reduce energy consumption while maintaining or improving machining performance.
• We have employed modeling techniques and experimental data to optimize machining parameters. The project likely aimed to identify the ideal combination of cutting speed, feed rate, and depth of cut to achieve efficient material removal while meeting quality standards.
• The cost benefit analysis has been onducted to assess the economic feasibility of the proposed machining processes. This analysis would consider the overall costs associated with energy-efficient and sustainable machining methods in comparison to traditional approaches.
• Machine learning models were used to develop and simulate the machining process, considering metallurgical, tribological, and sustainability factors. These models would aid in understanding the complex interactions and predicting the performance of different machining scenarios.
• The results and outcomes were collaborated with industry partners, such as aerospace manufacturers or machining companies, to ensure that the developed processes align with practical applications and industry requirements.

 

The potential outcomes and impacts are listed below:

1. Optimum machining parameters: During the project duration, the process parameters were Identified and optimized for the new metastable beta titanium alloy, resulting in efficient material removal and improved machining performance.

Impact: Aerospace manufacturers and machining companies benefit from reduced machining time, energy savings, and enhanced productivity.

2. Tool life enhancement: The developed strategies were  used to enhance tool life and wear resistance, reducing the frequency of tool changes and associated downtime.

• Impact: Machining companies experience cost savings due to decreased tooling expenses and increased operational efficiency.

3. Studies on metallurgical properties: The project objectives enhanced the metallurgical properties of machined components, ensuring they meet or exceed aerospace standards for reliability and safety.

• Impact: Aerospace industry stakeholders benefit from components with improved mechanical properties, contributing to the overall performance and safety of aircraft engines.

4. Publication and Knowledge Dissemination: Contributed to the scientific community through publications, presentations, and knowledge dissemination about energy-efficient machining of the alloy.

• Impact: Researchers, academics, and professionals in the field benefit from the shared knowledge, potentially inspiring further advancements in the machining of titanium alloys for aerospace applications.