Evolution of 3D chip morphology and phase transformation in dry drilling Ti6Al4V alloys

Zhu, Zhaoju; Guo, Kai; Sun, Jie; Li, Jianfeng; Liu, Yang; Chen, Lei; Zheng, Yihao

doi:10.1016/j.jmapro.2018.07.001

Cited by 51 publications

(20 citation statements)

References 19 publications

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“…Moreover, as shown in Figure 8, it was also observed that, the higher the feed, and the smaller the cutting speed, and the greater the distance between two adjacent cones of the chip (geometrical parameter known as "pitch"). This effect also enhances chip breakability [21]. Similar results were obtained for the laminated specimen.…”

Section: Mechanical Properties and Workpiece Microstructure Charactersupporting

confidence: 81%

“…Assessment of burr height was performed using a Leica DCM 3D confocal microscope (Wetzlar, Germany) at four equally-spaced positions around the hole periphery with an average calculation of the obtained data for each hole. Moreover, the overall chip geometry was also evaluated following the procedure proposed by Zhu et al [21].…”

Section: Experimental Setup For Drilling Testsmentioning

confidence: 99%

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Experimental Investigation of the Influence of Wire Arc Additive Manufacturing on the Machinability of Titanium Parts

Alonso

Veiga

Suárez

et al. 2019

Metals

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The manufacturing of titanium airframe parts involves significant machining and low buy-to-fly ratios. Production costs could be greatly reduced by the combination of an additive manufacturing (AM) process followed by a finishing machining operation. Among the different AM alternatives, wire arc additive manufacturing (WAAM) offers deposition rates of kg/h and could be the key for the production of parts of several meters economically. In this study, the influence of the manufacturing process of Ti6Al4V alloy on both its material properties and machinability is investigated. First, the mechanical properties of a workpiece obtained by WAAM were compared to those in a conventional laminated plate. Then, drilling tests were carried out in both materials. The results showed that WAAM leads to a higher hardness than laminated Ti6Al4V and satisfies the requirements of the standard in terms of mechanical properties. As a consequence, higher cutting forces, shorter chips, and lower burr height were observed for the workpieces produced by AM. Furthermore, a metallographic analysis of the chip cross-sectional area also showed that a serrated chip formation is also present during drilling of Ti6Al4V produced by WAAM. The gathered information can be used to improve the competitiveness of the manufacturing of aircraft structures in terms of production time and cost.

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Section: Mechanical Properties and Workpiece Microstructure Charactersupporting

confidence: 81%

Section: Experimental Setup For Drilling Testsmentioning

confidence: 99%

Experimental Investigation of the Influence of Wire Arc Additive Manufacturing on the Machinability of Titanium Parts

Alonso

Veiga

Suárez

et al. 2019

Metals

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“…Nowadays titanium alloys are being extensively used in aeronautical monolithic components thanks to their excellent mechanical properties. However, titanium and its alloys have been recognized as difficult-to-machine materials [1]. The productivity in machining titanium alloys is adversely restricted because of the low machinability [2].…”

Section: Introductionmentioning

confidence: 99%

Reliability assessment of cutting tools based on zero-failure data

Yang¹,

Guo²,

Feng³

et al. 2020

Preprint

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Titanium alloys are widely utilized in aeronautical monolithic components due to their excellent mechanical properties. However, the low machinability of titanium alloys results in an uncertain lifetime of cutting tools. Reliability assessment on cutting tools has become more and more significant to the effectiveness and stability of machining systems. Considering that cutting tools are often replaced well before the end of their useful lifetime to avoid failures and thus few tools failure data can be obtained during the machining process of titanium alloys, a reliability assessment model based on zero-failure data is developed to evaluate the reliability of cutting tools. A Weibull distribution model is chosen to describe the life distribution of cutting tools for reliability evaluation. Matching distribution curve method and weighted least squares method are used to estimate the distribution parameters. A novel approach using hierarchical Bayesian method for estimating the prior distribution of failure probability with zero-failure data is proposed by combining the characteristics of Weibull distribution and Incomplete Beta distribution. Reliability analysis for cutting tools with zero-failure data is performed using the proposed method. By comparing with the experience of experts and adopting stochastic simulation, the results of point estimation show plausibility of the proposed approach.

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“…Titanium alloy has the advantages of high specific strength (strength-to-density ratio), high temperature resistance and corrosion resistance, and is widely used in aerospace, biomedicine, automobile, chemical and other fields. 1 It accounts for 40% of all material removal processes because Tsao requires a large number of holes when assembling with rivets and bolts. 2…”

Section: Introductionmentioning

confidence: 99%

“…Zhu et al. 1 concluded that the continuous chip is easy to entangle the tool body and is bent by the tool holder. When the frictional torque generated between the hole wall and the chip exceeds the breaking torque of the tool, the bit may be broken.…”

Section: Introductionmentioning

confidence: 99%

Study on ultrasonic-assisted drilling of Ti6Al4V using 3-flute drill in the finite element simulation

Wang

2019

Proceedings of the Institution of Mechanical Engineers, Part C:

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Continuous chip is one of the major problems during drilling Ti6A14V, and chip breaking is dependent on many factors such as drilling parameters, tool geometries and type of drill bits used. This paper attempts to analyze the effect of various drilling parameters such as feed rate, spindle speed on performance characteristics such as chip morphology, thrust force, temperature, and tool wear in conventional drilling and ultrasonic-assisted drilling of Ti6A14V using twist drill bit and 3-flute drill bit in order to optimize the chip breakability of Ti6A14V. The twist and 3-flute drill bit are utilized to establish the finite element models to simulate the drilling process with Lagrangian approach in DEFORM-3D software. The results of the simulations not only reveal obvious varying regular pattern of thrust force, temperature, tool wear depth, chip thickness and damage with the increasing of feed rates, spindle speeds, which confirm the capability and advantage of finite element model of the drilling process, but also provide a more profound knowledge about the drilling mechanism including the effect of 3-flute drill bit in ultrasonic-assisted drilling on chip breakability and tool wear.

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Evolution of 3D chip morphology and phase transformation in dry drilling Ti6Al4V alloys

Cited by 51 publications

References 19 publications

Experimental Investigation of the Influence of Wire Arc Additive Manufacturing on the Machinability of Titanium Parts

Experimental Investigation of the Influence of Wire Arc Additive Manufacturing on the Machinability of Titanium Parts

Reliability assessment of cutting tools based on zero-failure data

Study on ultrasonic-assisted drilling of Ti6Al4V using 3-flute drill in the finite element simulation

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