The Effect of Cutting Parameters on Surface Roughness and Morphology of Ti-6Al-4V ELI Titanium Alloy during Turning with Actively Driven Rotary Tools
Round 1
Reviewer 1 Report
In this submission surface integrity of Ti-6Al-4VELI alloy after turning with actively driven rotary tools is described. This subject is interesting; however, some remarks should be done:
1. The surface integrity concept is much broader than surface texture that was studied in this submission; so the Title should be changed,
2. Keywords are poor and should be improved,
3. Non-typical abbreviation (ADRT) cannot be used as keyword,
4. The round tool insert should be described in detail to understand its idea, all angles should be shown in such scheme; is this tool a circular cutter with one wedge?
5. Results of FEM investigations should not be considered in “Materials and Methods” section; FRM should be added to Keywords,
6. The name of Table 2 is misguided,
7. When cutting investigations we study cutting speeds, not rotary speed; main angles in cutting are rake angle and clearance angle, not inclination angle; angles mentioned should be measured or calculated according ISO standard,
8. Surface Integrity concept is much broader than Surface Texture and only one of its parameters, namely Ra, was studied in this submission; so the paper Title should be changed,
9. According ISO standard, Ra parameter is correctly named as “the arithmetic average value of filtered roughness profile determined from deviations about the center line within the evaluation length; the authors cannot named Ra as Surface roughness,
10. This also applies to Rz,
11. There are a lot of equations for calculating Ra and Rz, and the authors need to pre-discuss them, because the some equations presented in submission are analogous, i.e. unnecessary,
12. In 3.2 section, a surface morphology is a part of surface layer, not machine3d surface; it should be well-thought-out.
Author Response
Dear Reviewer,
First of all, we deeply appreciate your helpful comments. We understand that the comments and suggestions are to improve the quality of this manuscript. In the following, several explanations and improvements are provided based on reviewers' comments and suggestions.
Comment 1: The surface integrity concept is much broader than surface texture
that was studied in this submission; so the Title should be changed.
Reply to comment 1:
The title has been changed to “The Effect of Cutting Parameters on Surface Roughness and Morphology of Ti-6Al-4V ELI Titanium Alloy during Turning with Actively Driven Rotary Tools” which focuses on surface roughness and surface morphology.
Comment 2: Keywords are poor and should be improved
Reply to comment 2:
The keyword has been improved, where it can be seen inside the manuscript revision.
Comment 3: Non-typical abbreviation (ADRT) cannot be used as keyword.
Reply to comment 3:
The keyword has been improved, where it can be seen inside the manuscript.
Comment 4: The round tool insert should be described in detail to understand its idea, all angles should be shown in such scheme; is this tool a circular cutter with one wedge?
Reply to comment 4:
Thank you for your valuable comment. In this study, the cutting tool that was used to cut the titanium alloy is a round insert tool, which has one circular cutting edge (wedge). The round insert tool can be drawn in detail in Figure 4.a of the manuscript revision (page 6).
Comment 5: Results of FEM investigations should not be considered in “Materials and Methods” section; FRM should be added to Keywords.
Reply to comment 5:
FEM analyses of the Rotary Tool Holder Structure have been proposed as a new section and placed after the introduction section (page 3 -5).
Comment 6: The name of Table 2 is misguided,
Reply to comment 6:
The name of Table 2 has been revised.
Comment 7: When cutting investigations we study cutting speeds, not rotary speed; main angles in cutting are rake angle and clearance angle, not inclination angle; angles mentioned should be measured or calculated according ISO standard,
Reply to comment 7:
Based on several literature of Turning with ADRT that is cited in this manuscript, for example in the journal with the title “Turning of difficult-to-machine materials with actively driven rotary tool’’ [Hosokawa], it is described that there are several cutting parameters that are involved in the turning with ADRT, namely tool diameter, cutting speed, tool revolution speed, feed, depth of cut, and tool inclination angle, which are also applied in this study. Actually, there are several cutting parameters that are different from conventional turning, namely tool revolution speed (rpm) or tool peripheral speed (m/min) and inclination angle (deg.). An overview of the cutting parameters of turning with ADRT can be depicted in Figure 4.a of the manuscript revision (page 6).
Comment 8: Surface Integrity concept is much broader than Surface Texture and only one of its parameters, namely Ra, was studied in this submission; so the paper Title should be changed.
Reply to comment 8:
The title has been changed
Comment 9: According ISO standard, Ra parameter is correctly named as “the arithmetic average value of filtered roughness profile determined from deviations about the center line within the evaluation length; the authors cannot named Ra as Surface roughness.
Reply to comment 9:
We have revised and emphasized at the end of the introduction of manuscript revision that this study focuses on the experimental investigation of the effect of turning parameters with ADRT on the surface roughness in terms of average surface roughness (Ra), see page 3.
Comment 10: This also applies to Rz,
Reply to comment 10:
Also applied to Rz, see page 12.
Comment 11: There are a lot of equations for calculating Ra and Rz, and the authors need to pre-discuss them, because the some equations presented in submission are analogous, i.e. unnecessary,
Reply to comment 11:
We can honestly say that because of the difficulty of finding literature on the Ra or Rz equation relevant to turning with ADRT (rotary tool), we developed the Ra or Rz equation based on the relationship between the inclination angle of the tool and surface roughness during turning with ADRT. The purpose of developing this equation is to explain the effect of the inclination angle on the surface roughness.
Comment 12: In 3.2 section, a surface morphology is a part of surface layer, not machine3d surface; it should be well-thought-out.
Reply to comment 12:
Thank you for your valuable comment. We agree with you that a surface morphology is a part of surface layer. Therefore, we would like to explain that in this study, part of the titanium material which was investigated microscopically for its surface morphology using SEM is the machined surface layer and the machined subsurface layer (underneath the machined surface). We have revised and emphasized in the revision of the manuscript that microscopic surface morphology investigations of the two parts (machined surface layer and underneath the machined surface) were to determine the possibility of surface damage. This was stated on page 12-15.
Reviewer 2 Report
Reviewer comments
This paper stated on the “Experimental Investigation on Surface Integrity of Ti-6Al-4VELI Titanium Alloy during Turning with Actively Driven Rotary Tools”. This paper has been written well with high quality of scientific research. However, some parts should be revised before publication.
1- The title of paper is too simple and it was not interesting to read. It should be modified.
2- In abstract section, the sentence from line:9-10 is not clear. Because there are more superior mechanical properties of Ti-6Al-4V ELI (e.g., high strength, low density, high fracture toughness, and superior biocompatibility) that make Ti-6Al-4V ELI suitable used in medical implant application.
3- The introduction part of the paper has been stated well. However, more citations related to “turning process with ADRT on Ti-6Al-4V ELI” should be added. Also, titanium can be processed by turning via Monolithic Driven Rotary Tool (MDRT). What is main different between MDRT and ADRT?
4- More clearly image of Actively Driven Rotary Tools should be added. Fig. 1 is not clear. Improve the quality of this figure.
5- For medical implant products, clean and smooth surface of materials are demanded. The surface roughness Ra should be lower than 0.05 μm. According to the results of this paper, I think that the “Turning process with Actively Driven Rotary Tools” used in this paper has limitation in terms of the reduction in surface roughness.
Author Response
Dear Reviewer,
We thank you very much for your comments and suggestions on our manuscript. We understand that the comments and suggestions are to improve the quality of this manuscript. In the following, several explanations and improvements are provided based on reviewers' comments and suggestions.
Comment 1: The title of paper is too simple and it was not interesting to read. It should be modified.
Reply to comment 1: The title has been changed to “The Effect of Cutting Parameters on Surface Roughness and Morphology of Ti-6Al-4V ELI Titanium Alloy during Turning with Actively Driven Rotary Tools” so that interesting to read.
Comment 2: In abstract section, the sentence from line:9-10 is not clear. Because there are more superior mechanical properties of Ti-6Al-4V ELI (e.g., high strength, low density, high fracture toughness, and superior biocompatibility) that make Ti-6Al-4V ELI suitable used in medical implant application.
Reply to comment 2: We have revised the abstract section. This material has the characteristics of corrosion resistance, high strength, and lightweight. We understand that the corrosion resistance is related to the superior biocompatibility. The good corrosion behavior will prevent degradation of the material in the physiological environment and therefore will promote biocompatibility. In addition, low density of mechanical properties of Ti-6Al-4V ELI is related to lightweight material, so that it burdens the bones.
Comment 3: The introduction part of the paper has been stated well. However, more citations related to “turning process with ADRT on Ti-6Al-4V ELI” should be added. Also, titanium can be processed by turning via Monolithic Driven Rotary Tool (MDRT). What is main different between MDRT and ADRT?
Reply to comment 3: The citation related to “turning process with ADRT on Ti-6Al-4V ELI”, that is Effects of Process Cutting Parameters on the Ti-6Al-4V Turning with Monolithic Driven Rotary Tool. In principle, MDRT and ADRT are relatively the same. MDRT uses only solid tools where the cutting edge is attached to the tool holder. While ADRT generally uses insert tools. We would like to inform you that the article was published recently and coincides with our article submission process. Therefore, we did not have time to cite the article.
Comment 4: More clearly image of Actively Driven Rotary Tools should be added. Fig. 1 is not clear. Improve the quality of this figure.
Reply to comment 4: We have revised the quality of that figure; can be seen in page 6.
Comment 5: For medical implant products, clean and smooth surface of materials are demanded. The surface roughness Ra should be lower than 0.05 µm. According to the results of this paper, I think that the “Turning process with Actively Driven Rotary Tools” used in this paper has limitation in terms of the reduction in surface roughness.
Reply to comment 5: Thank you for your valuable comment. We agree that the surface roughness obtained in this study is still not classified as smooth for implant products. Therefore, we add the explanation "The damage on the machined surface of implant material (Ti-6Al-4V ELI) has to be avoided so that it has good biocompatibility. However, the average surface roughness value obtained in this study is still not classified as smooth for implant products, in which a smooth implant surface is required in the range of 0.00-0.4 micro-meter of average surface roughness (Ra)," which we state on page 14, the first paragraph of the manuscript revision.
Round 2
Reviewer 2 Report
The quality of paper has been improved very much. The authors have addressed all my concerns.
This paper can be accepted for the publication.
Best regards,
