Analysis of Microstructure and Chip Formation When Machining Ti-6Al-4V

Shyha, Islam; Gariani, Salah; El‐Sayed, M. A.; Huo, Dehong

doi:10.3390/met8030185

Cited by 24 publications

(6 citation statements)

References 50 publications

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“…After high-speed milling of Ti-6Al-4V and Ti-834, the microstructural subsurface damage in the form of intense slip bands was identified by Thomas et al Due to a reduction in fatigue crack initiation resistance, the microstructural subsurface damage could degrade the in-service properties of workpiece [70]. Shyha et al [71] studied the influence law of cutting fluid supply system on metallurgical characteristics, and concluded that cutting fluid had little influence on the microstructure and deformation layer of cutting subsurface; cutting speed was a key factor affecting microstructure. Li et al [72] carried out an experimental study on hard milling of AISI H13 steel, and the results showed that the nanohardness and plastic deformation depth of the machined surface increased with the increase of the grinding radius of the cutting edge.…”

Section: Machined Surface Metallurgy Characteristicmentioning

confidence: 99%

Part Functionality Alterations Induced by Changes of Surface Integrity in Metal Milling Process: A Review

et al. 2018

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It has been proved that surface integrity alteration induced by machining process has a profound influence on the performance of a component. As a widely used processing technology, milling technology can process parts of different quality grades according to the processing conditions. The different cutting conditions will directly affect the surface state of the machined parts (surface texture, surface morphology, surface residual stress, etc.) and affect the final performance of the workpiece. Therefore, it is of great significance to reveal the mapping relationship between working conditions, surface integrity, and parts performance in milling process for the rational selection of cutting conditions. The effects of cutting parameters such as cutting speed, feed speed, cutting depth, and tool wear on the machined surface integrity during milling are emphatically reviewed. At the same time, the relationship between the machined surface integrity and the performance of parts is also revealed. Furthermore, problems that exist in the study of surface integrity and workpiece performance in milling process are pointed out and we also suggest that more research should be conducted in this area in future.

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Section: Machined Surface Metallurgy Characteristicmentioning

confidence: 99%

Part Functionality Alterations Induced by Changes of Surface Integrity in Metal Milling Process: A Review

et al. 2018

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“…However these technics cannot be directly applied to gear teeth surfaces improvement due to the specific geometric shape of gear teeth. While the phenomena which occur during machine cutting or abrasive machining process and their effect on the surface layer are widely discussed in the available references [ 9 , 10 , 11 , 12 , 13 , 14 , 15 , 16 , 17 , 18 ] and the industry norms applied in the assessment of microstructure, the question of machining prior to case carburizing of the surfaces to be exposed to considerable and dynamically variable loads is less extensively detailed in research work. However, it is known, that certain external factors related to machining could result in local changes in the carburized case parameters to a point capable of negatively affecting the mechanical performance of the carburized case.…”

Section: Introductionmentioning

confidence: 99%

The Effect of Chip Binding on the Parameters of the Case-Hardened Layer of Tooth Surfaces for AMS 6308 Steel Gears Processed by Thermochemical Treatment

Fularski¹,

Filip

2021

Materials

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The following article describes influence of pressure welded or bound chips to the gear tooth flank and/or the tooth root on a carburized case and surface layer hardness of Pyrowear 53 steel gears, machined by Power Skiving method. This paper is focused only on one factor, the chips generated while forming gear teeth by power skiving, which could result in local changes in the carburized case parameters as a negatively affecting point of mechanical performance of the carburized case. The chips, due to the specifics of the power skiving process and the kinematics of tooth forming, could be subject to the phenomena of pressure welding or binding of chips to the tooth. During the carburizing stage of the downstream manufacturing processes, the chips form a diffusion barrier, which ultimately could result in localized changes in the carburized case. This work was an attempt to answer the question of how and to what extent the chips affect the case hardening. Performed simulations of chips by a generating cupper “spots”, mentioned in the study, represent a new approach in connection with minimization of errors, which could appear during carbon case depth and case hardness analysis for typical chips, generated during the machining process—assurance that a complete chip was bound to the surface. Hardness correlation for zones, where the chip appears with areas free of chips, gives simple techniques for assessment. Performed tests increased the knowledge about the critical size of the chip—1.5 mm, which could affect the case hardening. Obtained experimental test results showed that the appearance of chip phenomena on the gear tooth might have a negative impact on a carburized case depth and hardened layer.

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“…Based on the experimental data, Patwari et al [14] developed the chip serration frequency prediction model in high-speed end milling of S45C steel using TiN inserts, and its prediction accuracy was 95%. Under other operating conditions, such as the step shoulder downmilling of Ti-6Al-4V [15], the combination of friction drilling and form tapping process for making 'nutless' bolted joints [16] and the orthogonal cutting of hardened low alloy steel 51CrV4 + Q [17], plentiful valuable research findings regarding chip morphology have also been yielded. Unfortunately, these findings were obtained under the condition of fixed process parameters and do not involve the sudden change of chip morphology, so they can not be applied to the modeling of CSC.…”

Section: Introductionmentioning

confidence: 99%

Experimental Investigation and Bifurcation Set Equation Modeling of Chip-Splitting Catastrophe

You¹,

Xu²,

Zhu³

et al. 2021

Preprint

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This paper presents the methods of designing experiments for observation of the critical conditions of chip-splitting catastrophe (CSC) based on the dichotomy principle and the methodology of modelling CSC with a bifurcation set equation on the basis of catastrophe theory. 355 groups of experiments are carried out for observing critical conditions of CSC in the symmetrical straight double-edged cutting. It is found that the occurrence of CSC is of obvious regularity. Besides, the specific cutting force is reduced by a maximum of 64.68% after CSC. The bifurcation set equation is established, which can predict the critical conditions of CSC in the symmetrical cutting with a straight double-edged tool with any combinations of cutting edge angles and rake angles. With verification, the predicted values of the critical cutting thickness of CSC based on the established equation are in good agreement with experimental values and yield an average absolute prediction error of 5.34%, which is satisfactorily low. This study lays the groundwork for energy-saving optimization of tool structure and process parameters through reasonable utilization of CSC.

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Analysis of Microstructure and Chip Formation When Machining Ti-6Al-4V

Cited by 24 publications

References 50 publications

Part Functionality Alterations Induced by Changes of Surface Integrity in Metal Milling Process: A Review

Part Functionality Alterations Induced by Changes of Surface Integrity in Metal Milling Process: A Review

The Effect of Chip Binding on the Parameters of the Case-Hardened Layer of Tooth Surfaces for AMS 6308 Steel Gears Processed by Thermochemical Treatment

Experimental Investigation and Bifurcation Set Equation Modeling of Chip-Splitting Catastrophe

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