Experimental analysis and characterisation of chip segmentation in dry machining of Ti-6Al-4V alloy using inserts with hybrid textures

Siju, Amal S.; Jose, Sandeep; Waigaonkar, Sachin

doi:10.1016/j.cirpj.2021.12.004

Cited by 10 publications

(4 citation statements)

References 62 publications

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“…The thickness of separated segments is in the micrometer range. The specificity of surface finishing using lapping films lies in the fact that the thickness of the chip segment is expressed in nanometers, resulting in enormous material separation frequencies at the megahertz level [38][39][40][41]. Chip segmentations arise during high-speed machining due to the formation of adiabatic shear bands [42,43].…”

Section: Research On Microchips Lapping Film Finishing Productsmentioning

confidence: 99%

Morphology of Microchips in the Surface Finishing Process Utilizing Abrasive Films

Tandecka,

Kacalak,

Wiliński

et al. 2024

Materials

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In this study, the surface of new lapping films was analyzed, and the lapping finishing process was applied to RG7 tin bronze alloy. The research focused on examining lapping films with electrocorundum grains of nominal sizes 30, 12, and 9 μm, commonly used for achieving smooth surfaces. The manufacturing process involves placing abrasive grains and binder onto a polyester tape, resulting in a heterogeneous distribution of abrasive grains. The study investigates the impact of this random distribution on the performance of lapping films during material removal. Scanning electron microscopy was used to analyze the surface structure of abrasive films, revealing distinctive structures formed by the specific aggregation of abrasive grains. This study explores the influence of different nominal grain sizes on surface finish and aims to optimize lapping processes for diverse applications. The research also delves into microchip analysis, examining the products of the lapping film finishing process. Microchips were observed directly on the abrasive tool surface, revealing insights into their morphology and distribution. The chip segmentation frequency was determined, and they amounted to approximately 0.8 to 3 MHz; these are very high frequencies, which are unique for known chip-forming processes.

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Section: Research On Microchips Lapping Film Finishing Productsmentioning

confidence: 99%

Morphology of Microchips in the Surface Finishing Process Utilizing Abrasive Films

Tandecka,

Kacalak,

Wiliński

et al. 2024

Materials

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“… Lubrication method: dry machining. [ 15 ] Micro pyramid Protrusion Depth—155 mm Groove interval D 45.6 mm Texture manufacturing method: Laser texturing. Textured surface: rake face.…”

Section: Table A1mentioning

confidence: 99%

“…In the literature, there have been published works on texturing the surface of cutting tools, in which their effect on friction and wear were studied [ 15 , 16 , 17 , 18 , 19 , 20 , 21 , 22 , 23 , 24 ]. These studies showed that this approach allows for improving the tribological properties in the tool–chip interface, reducing the machining temperature, the rate of tool wear and the cutting forces, and consequently obtaining an increase in machining productivity [ 25 ].…”

Section: Introductionmentioning

confidence: 99%

The Influence of Surface Texturing of Ceramic and Superhard Cutting Tools on the Machining Process—A Review

et al. 2022

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Machining is an indispensable manufacturing process for a wide range of engineering materials, such as metals, ceramics, and composite materials, in which the tool wear is a serious problem, which affects not only the costs and productivity but also the quality of the machined components. Thus, the modification of the cutting tool surface by application of textures on their surfaces is proposed as a very promising method for improving tool life. Surface texturing is a relatively new surface engineering technology, where microscale or nanoscale surface textures are generated on the cutting tool through a variety of techniques in order to improve tribological properties of cutting tool surfaces by reducing the coefficient of friction and increasing wear resistance. In this paper, the studies carried out to date on the texturing of ceramic and superhard cutting tools have been reviewed. Furthermore, the most common methods for creating textures on the surfaces of different materials have been summarized. Moreover, the parameters that are generally used in surface texturing, which should be indicated in all future studies of textured cutting tools in order to have a better understanding of its effects in the cutting process, are described. In addition, this paper proposes a way in which to classify the texture surfaces used in the cutting tools according to their geometric parameters. This paper highlights the effect of ceramic and superhard textured cutting tools in improving the machining performance of difficult-to-cut materials, such as coefficient of friction, tool wear, cutting forces, cutting temperature, and machined workpiece roughness. Finally, a conclusion of the analyzed papers is given.

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“…Shear Angle: 𝜙 = tan −1 (r) t0 is feed rate and 𝑡 𝐶 is the actual chip thickness (mean value of chip tooth's peak and valley) Dry-Turning Ti-6Al-4V [34], [48]- [51] Model-4 Shear Angle:…”

Section: Introductionmentioning

confidence: 99%

Impact of Dry and Cryogenic Cutting Medium on Shear Angle and Chip Morphology in High-speed Machining of Titanium Alloy (Ti-6Al-4V)

Hassan,

Khan,

Younas

et al. 2024

Int. J. Automot. Mech. Eng.

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Ti-6Al-4V, a titanium alloy, is widely employed in various engineering sectors due to its attractive combination of strong corrosion resistance and specific strength. However, titanium alloys frequently result in serrated chips, which present considerable machinability issues compared to other materials. The cutting medium plays a vital role in the chip formation mechanism, further affecting the machined part integrity and thermo-mechanical properties. Chip morphological parameters such as shear angle, compression ratio, and segmentation degree are essential aspects of estimating machined part surface roughness, tool wear, cutting forces, and energy consumption. Therefore, it is important to understand the entire mechanism of chip formation in terms of chip morphology in high-speed cutting. This fundamental research aims to analyze and compare the shear angle model and chip formation of titanium alloy Ti-6Al-4V for cutting speeds ranging from 50 m/min to 150 m/min and feed rates ranging from 0.12 mm/rev to 0.24 mm/rev under dry and cryogenic cutting environments. Single-point turning experiments were conducted on Ti-6Al-4V workpieces with uncoated tungsten carbide inserts (without chip breakers), which are advantageous for heat transfer. After the chip analysis, it was observed that the shear angle obtained practically with model-4 is the most appropriate model for shear angle calculation, and the cryogenic cutting medium is suitable for Ti-6Al-4V machining. At the feed rate of 0.12-0.24 mm/rev and cutting speed of 50-150 m/min, the shear angle in dry-medium machining ranges from 32° to 42°, while in cryogenic medium machining, it ranges from 34.6° to 44.6°. Overall, a larger shear angle has been observed in cryogenic turning compared to dry turning, which is advantageous for reduced cutting forces owing to a lesser shear plane. The tool-chip contact length, which is the intimate contact between the tool face and chip surface, significantly decreases under cryogenic media. A smaller tool-chip contact length results in an elevated shear angle, which improves process sustainability and economy during cryogenic turning, as described.

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Experimental analysis and characterisation of chip segmentation in dry machining of Ti-6Al-4V alloy using inserts with hybrid textures

Cited by 10 publications

References 62 publications

Morphology of Microchips in the Surface Finishing Process Utilizing Abrasive Films

Morphology of Microchips in the Surface Finishing Process Utilizing Abrasive Films

The Influence of Surface Texturing of Ceramic and Superhard Cutting Tools on the Machining Process—A Review

Impact of Dry and Cryogenic Cutting Medium on Shear Angle and Chip Morphology in High-speed Machining of Titanium Alloy (Ti-6Al-4V)

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