Finite element modelling of combined turning/burnishing effects on surface integrity of Ti6Al4V alloy

Rotella, Giovanna; Saffioti, Maria Rosaria; Sanguedolce, Michela; Umbrello, Domenico

doi:10.1007/s00170-021-08219-4

Cited by 11 publications

(6 citation statements)

References 29 publications

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“…By measuring the wear track area an estimation of depth with respect to worked surface can be made showing that up to 3000 m of distance covered, wear track depth below the surface is in the order of 200 µm. As a matter of fact, it has been demonstrated that the effects of burnishing process under these conditions in terms of hardness and residual stresses are accentuated up to the mentioned depth below surface, and gradually decrease [11] thus giving an explanation to the above. Another concurrent factor is given by the reduction of surface asperities on AB surfaces with respect to the other conditions, as demonstrated by surface analysis and roughness measurements.…”

Section: Achievements and Trends In Materials Formingmentioning

confidence: 92%

Tribocorrosion Behavior of Ti6Al4V Machined and Burnished Components for Biomedical Application

Rotella

Saffioti

Sanguedolce

et al. 2022

KEM

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Nowadays, the increased average age of patients and the decreased age at which arthroplasty is carried out represents a reason for the necessity of higher quality standards for prostheses. In particular, tribocorrosion generates an irreversible transformation of the materials and the release of particles and metal ions in toxic concentrations in the biological environment in which the systems are implanted. One of the most used materials for prosthetic implants is the Ti6Al4V alloy but its tribological behavior is still challenging for the application. Employing and optimizing severe plastic deformation processes represents a way to obtain prostheses with superior performance improving patients’ quality of life and reducing the burden on National Health Cares. Ti6Al4V bars have undergone machining with semi-finishing parameters and burnishing processes. Tribocorrosion tests have been performed in a custom-made cylinder-on-disk configuration employing Al2O3 counterparts and phosphate buffer solution with the addition of albumin as simulated body fluid. The effects of sole machining and its combination with burnishing on surface quality and specific wear rate (SWR) have been assessed with respect to as received surface conditions. Optical microscopy, stylus profilometry and sample weighing before tests and at specific intervals during the tests have been employed for characterization. As a main result, it has been found that burnishing process is able to improve SWR of Ti6Al4V samples with respect to both as received and machined samples. Furthermore, the overall behavior of tribological system is gradually improved first employing sole machining and then combining machining and burnishing, reducing SWR of counterparts as well.

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Section: Achievements and Trends In Materials Formingmentioning

confidence: 92%

Tribocorrosion Behavior of Ti6Al4V Machined and Burnished Components for Biomedical Application

Rotella

Saffioti

Sanguedolce

et al. 2022

KEM

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“…This map reveals the local variations of lattice orientations due to the presence of dislocations which therefore can be considered a manifestation of the residual strain. Generally, KAM is high in deformed grains due to higher dislocation density [44,45]. The area near the surface representing higher KAM values (coloured region with green, yellow and red) is confined to a thin layer for all conditions, indicating a relaxed surface developed through the CBF procedure.…”

Section: Evaluation Of the Cbf Processed Ti-6al-4 V Microstructurementioning

confidence: 94%

A comprehensive investigation of abrasive barrel finishing on hardness and manufacturability of laser-based powder bed fusion hollow components

Khorasani

Ghasemi

Farabi

et al. 2022

Int J Adv Manuf Technol

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One of the main issues of laser-based powder bed fusion (LB-PBF) parts is surface quality and dimensional deviations, which require post-processing. Conventional post-processing such as turning and milling cannot machine internal surfaces and therefore is not suitable for hollow components. In this paper, Ti–6Al–4 V components with different hollow shapes were printed by LB-PBF and post-processed by centrifugal barrel finishing (CBF). Samples were printed based on Taguchi L18 design of experiments (DoE) on the (L18: 21 × 33) matrix and polished in abrasive solution by porcelain triangular media 2 × 2 mm. The effect of process parameters including rotation direction, speed, time and volumetric percentage of abrasive on hardness and manufacturability, including surface quality, material removal rate (MRR) and dimensional deviation, are discussed. The novelty of this work is the application of this process to clean both the internal and external surfaces of LB-PBF parts, where previously it has only been investigated for external surfaces. This paper scrutinized the performance of the CBF on internal geometries, and it was shown for the size of the investigated components, the hexagonal hollow achieved the highest maximum removal rate over the square and circular hollows. In addition, the effect of CBF on plastic deformation and microstructural characterization has been investigated to find the effect of this process on work hardening. The results of this study also show that the rotational speed and the volumetric percentage of the abrasive directly drive the MRR. A higher rotational speed increases the slope of the sliding path and the sliding speed between printed parts and abrasive media, which causes higher cutting and grinding, MRR and media wear rate.

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“…Previous studies showed a deeper analysis concerning the influence of the burnishing process parameters on the Ti6Al4V surface integrity. [26][27][28][29] Thus, for the tribological experimental campaign only the best and the worst burnishing cases were selected (respectively BB and WB) emerged from this previous tests (Table 1) together with the as-received and as-turned conditions (respectively AR and AT) with standard semi-finishing parameters, namely 30 m/min of cutting speed, feed of 0.15 mm/rev, and 0.1 mm of depth of cut. The as-received material was Ti6Al4V, grade 5 in form of a bar (30 mm starting diameter), with α equiaxed grains and intergranular β microstructure with 5 μm mean grain size (Figure 1).…”

Section: Methodsmentioning

confidence: 99%

Tribocorrosion experimental investigation on Ti6Al4V burnished samples used for hip joint replacement

Sicilia,

Saffioti,

Miorin

et al. 2024

Tribology - Materials, Surfaces & Interfaces

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This work aimed to investigate the effect of the burnishing surface treatment on the tribocorrosion resistance related to Ti6Al4V specimens, in the framework of the head-neck tribo-pair characterising a total hip replacement. The experimental procedure carried out started by choosing the specimens referred to different burnishing conditions together with specimens not treated or treated only with the turning process. Then, tribocorrosion experiments with fixed load and two frequencies were conducted through a reciprocating tribometer equipped with a potentiostat able to measure the electrochemical corrosion potential and current associated to the synergistic wear phenomenon analysed together with the coefficient of friction. Furthermore, optical topographical acquisitions were performed before and after the experiments. The results showed that the non-burnished specimens exhibited unexpected oscillations of the coefficient of friction approximately in the middle of the rubbing phase and the same happens for the cell potential; the wear volume was measured after the tribocorrosion test. This allowed to estimate the wear factor related to all the analysed configurations, showing a greater mean value in correspondence of greater sliding frequencies in the non-burnished cases, while the opposite happens in the burnished cases. Finally, the burnished sample at the lower burnishing force resulted to have the noblest corrosion potential, while the non-burnished samples exhibited the lowest corrosion current density.

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Finite element modelling of combined turning/burnishing effects on surface integrity of Ti6Al4V alloy

Cited by 11 publications

References 29 publications

Tribocorrosion Behavior of Ti6Al4V Machined and Burnished Components for Biomedical Application

Tribocorrosion Behavior of Ti6Al4V Machined and Burnished Components for Biomedical Application

A comprehensive investigation of abrasive barrel finishing on hardness and manufacturability of laser-based powder bed fusion hollow components

Tribocorrosion experimental investigation on Ti6Al4V burnished samples used for hip joint replacement

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