Subsurface Deformation After Dry Machining of Grade 2 Titanium

Dargusch, Matthew S.; Zhang, Mingxing; Palanisamy, Suresh; Buddery, Alexander; StJohn, David H.

doi:10.1002/adem.200700233

Cited by 17 publications

(11 citation statements)

References 20 publications

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“…1 External, internal features and influences after machining constituting the surface integrity [12,19] (a), surface morphology of a white layer according to [15,17] (b) tools, a change in the microstructure and, therefore, material properties has a significant influence on the process and on the surface morphology. Besides defects and external features of the surface, unfavourable milling process conditions may lead to unwanted subsurface morphology, called white layer formation, as for instance shown in [15][16][17], and an extensive a zone of plastic deformation, e. g. found by Dargusch et al [18], see Fig. 1b.…”

Section: Introductionmentioning

confidence: 97%

Surface finishing of hard-to-machine cladding alloys for highly stressed components

Schroepfer

Treutler

Boerner

et al. 2021

Int J Adv Manuf Technol

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The supply and processing of materials for highly stressed components are usually cost-intensive. Efforts to achieve cost and resource efficiency lead to more complex structures and contours. Additive manufacturing steps for component repair and production offer significant economic advantages. Machining needs to be coordinated with additive manufacturing steps in a complementary way to produce functional surfaces suitable for the demands. Regarding inhomogeneity and anisotropy of the microstructure and properties as well as production-related stresses, a great deal of knowledge is still required for efficient use by small- and medium-size enterprises, especially for the interactions of subsequent machining of these difficult-to-machine materials. Therefore, investigations on these influences and interactions were carried out using a highly innovative cost-intensive NiCrMo alloy (IN725). These alloys are applied for claddings as well as for additive component manufacturing and repair welding using gas metal arc welding processes. For the welded specimens, the adequate solidification morphology, microstructure and property profile were investigated. The machinability in terms of finishing milling of the welded surfaces and comparative analyses for ultrasonic-assisted milling processes was examined focussing on surface integrity. It was shown that appropriate cutting parameters and superimposed oscillating of the milling tool in the direction of the tool rotation significantly reduce the mechanical loads for tool and workpiece surface. This contributes to ensure a high surface integrity, especially when cutting has to be carried out without cooling lubricants.

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Section: Introductionmentioning

confidence: 97%

Surface finishing of hard-to-machine cladding alloys for highly stressed components

Schroepfer

Treutler

Boerner

et al. 2021

Int J Adv Manuf Technol

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“…To increase the productivity on the titanium machining shop floor, it is essential to either improve the material removal rate and/or the cutting tool life. In order to achieve the improved machinability of titanium, there are few critical factors to consider such as machining parameters, vibration, type of cutting tools/inserts used and also coolant delivery mechanisms [5][6][7][8][9][10]. Tool wear is considered as one of the major problems when machining titanium alloys.…”

Section: Introductionmentioning

confidence: 99%

Tool wear mechanisms involved in crater formation on uncoated carbide tool when machining Ti6Al4V alloy

Rashid

Palanisamy

Sun

et al. 2015

Int J Adv Manuf Technol

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When machining titanium alloys at cutting speeds higher than 60 m/min using cemented carbide cutting tools, the tool wears out rapidly. With the ever-increasing use of titanium alloys, it is essential to address this issue of rapid tool wear in order to reduce manufacturing costs. Therefore, the intention of this study was to investigate all possible tool wear mechanisms involved when using uncoated carbide cutting tools to machine Ti6Al4V titanium alloy at a cutting speed of 150 m/min under dry cutting conditions. Adhesion, diffusion, attrition, and abrasion were found to be the mechanisms associated with the cratering of the rake surface of the cutting tool. The plastic deformation of the cutting edge was also noticed which resulted in weakening of the rake surface and clear evidence has been presented. Based on this evidence, the process of the formation of the crater wear has been described in detail.

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“…The drill forces the silicon particles to break and disperse in the hole entrance region. The silicon particles broken in the cutting direction are directed toward the hole middle and exit regions by the effect of plastic deformation [24,52,53] and temperature (Figs. 9, 10, 11).…”

Section: Evaluation Of Machinability Propertiesmentioning

confidence: 99%

Machinability properties of Al–7Si, Al–7Si–4Zn and Al–7Si–4Zn–3Cu alloys

Bayraktar

Afyon

2020

J Braz. Soc. Mech. Sci. Eng.

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Al-7Si, Al-7Si-4Zn, Al-7Si-4Zn-3Cu alloys were produced by permanent mold casting method to investigate the effects of copper and zinc additions on the machinability properties of Al-7Si alloy. The structural and mechanical properties of the produced alloys were investigated with conventional methods. Machinability properties of these alloys were determined by turning, and they were associated with structural and mechanical properties of the alloys. Machinability experiments were carried out in CNC vertical machining center under dry cutting conditions using uncoated carbide drill and constant cutting speed (120 m/min), feed (0.15 mm/rev) and depth of cut (15 mm) values. The microstructure of Al-7Si binary alloy was observed to be composed of aluminum-rich α phase, primary silicon crystals and eutectic Al-Si phase. The addition of 4% Zn to the Al-7Si alloy did not form a different phase in the microstructure. However, Al 2 Cu intermetallic phase was formed by addition of 3% Cu. While the hardness and tensile strength of the alloy increased, elongation to fracture significantly reduced. As a result of machinability experiments, it was observed that the minimum thrust force and surface roughness occurred in Al-7Si-4Zn-3Cu alloy, while the maximum built-up edge was observed during drilling of Al-7Si and Al-7Si-4Zn alloys. Microhardness value of machined surface in Al-7Si alloy was found to be the minimum while the maximum Al-7Si-4Zn-3Cu alloy was observed.

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Subsurface Deformation After Dry Machining of Grade 2 Titanium

Cited by 17 publications

References 20 publications

Surface finishing of hard-to-machine cladding alloys for highly stressed components

Surface finishing of hard-to-machine cladding alloys for highly stressed components

Tool wear mechanisms involved in crater formation on uncoated carbide tool when machining Ti6Al4V alloy

Machinability properties of Al–7Si, Al–7Si–4Zn and Al–7Si–4Zn–3Cu alloys

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