Experimental investigation on the effect of the material microstructure on tool wear when machining hard titanium alloys: Ti–6Al–4V and Ti-555

Nouari, Mohammed; Makich, Hamid

doi:10.1016/j.ijrmhm.2013.04.011

Cited by 98 publications

(47 citation statements)

References 26 publications

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“…Titanium is chemically reactive and, therefore, has a tendency to weld to the cutting tool during machining leading to chipping and premature tool failure [5][6][7]. In addition, its low thermal conductivity (about 15 W/m K vs. 270 W/m K for the steel CRS1018 at 700 °C) increases the temperature at the tool/workpiece interface, which adversely affects the tool life.…”

Section: Introductionmentioning

confidence: 99%

“…In addition, its low thermal conductivity (about 15 W/m K vs. 270 W/m K for the steel CRS1018 at 700 °C) increases the temperature at the tool/workpiece interface, which adversely affects the tool life. Additionally, the high strength maintained at elevated temperature and low modulus of elasticity (50% less than that of the steel) further impairs the machinability of these materials [6][7][8][9]. According to Ezugwu [10], the tool wear in machining of titanium alloys is due to high stresses and high temperatures found near to the cutting edge.…”

Section: Introductionmentioning

confidence: 99%

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On the Physics of Machining Titanium Alloys: Interactions between Cutting Parameters, Microstructure and Tool Wear

Nouari

Makich

2014

Metals

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Abstract:The current work deals with the analysis of mechanisms involved during the machining process of titanium alloys. Two different materials were chosen for the study: Ti-6Al-4V and Ti-55531. The objective was to understand the effect of all cutting parameters on the tool wear behavior and stability of the cutting process. The investigations were focused on the mechanisms of the chip formation process and their interaction with tool wear. At the microstructure scale, the analysis confirms the intense deformation of the machined surface and shows a texture modification. As the cutting speed increases, cutting forces and temperature show different progressions depending on the considered microstructure (Ti-6Al-4V or Ti-55531 alloy). Results show for both materials that the wear process is facilitated by the high cutting temperature and the generation of high stresses. The analysis at the chip-tool interface of friction and contact nature (sliding or sticking contact) shows that machining Ti55531 often exhibits an abrasion wear process on the tool surface, while the adhesion and diffusion modes followed by the coating delamination process are the main wear modes when machining the usual Ti-6Al-4V alloy.

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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

On the Physics of Machining Titanium Alloys: Interactions between Cutting Parameters, Microstructure and Tool Wear

Nouari

Makich

2014

Metals

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“…Examination of the cutting tools used in these machining conditions revealed that coating delamination, adhesion, and abrasion are the major wear mechanisms in the cutting tool, shown in Figure 6. Coating delamination in coated carbide tools during machining of titanium alloys is more frequently observed by various authors [25][26][27]. This wear is attributed to the chemical reaction and crack propagation at the substrate interface [28].…”

Section: Tool Wear Mechanismsmentioning

confidence: 99%

Metallurgical and Machinability Characteristics of Wrought and Selective Laser Melted Ti-6Al-4V

Shunmugavel

Polishetty

Nomani

et al. 2016

Journal of Metallurgy

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This research work presents a machinability study between wrought grade titanium and selective laser melted (SLM) titanium Ti6Al-4V in a face turning operation, machined at cutting speeds between 60 and 180 m/min. Machinability characteristics such as tool wear, cutting forces, and machined surface quality were investigated. Coating delamination, adhesion, abrasion, attrition, and chipping wear mechanisms were dominant during machining of SLM Ti-6Al-4V. Maximum flank wear was found higher in machining SLM Ti-6Al-4V compared to wrought Ti-6Al-4V at all speeds. It was also found that high machining speeds lead to catastrophic failure of the cutting tool during machining of SLM Ti-6Al-4V. Cutting force was higher in machining SLM Ti-6Al-4V as compared to wrought Ti-6Al-4V for all cutting speeds due to its higher strength and hardness. Surface finish improved with the cutting speed despite the high tool wear observed at high machining speeds. Overall, machinability of SLM Ti-6Al-4V was found poor as compared to the wrought alloy.

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“…Coated cemented carbides have also been studied as an alternative in order to increase the duration of tool life [19,20]. However, the most frequently used coatings (TiC, TiN, Al 2 O 3, ZrC, HfC, etc.)…”

Section: Introductionmentioning

confidence: 99%

Influence of oxygen content on the machinability of Ti-6Al-4V alloy

Sacristan

Garay

Hormaetxe

et al. 2016

Int J Adv Manuf Technol

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Titanium alloys are widely employed in many aerospace components due to their high strength-toweight ratio, good corrosion resistance and fatigue properties, maintained at relatively high temperatures. Nevertheless, machining these materials efficiently has become a challenge in a sector that demands high productivity rates and minimal manufacturing times. This work analyses the machinability of the α + β Ti-6Al-4V alloy in rough turning. Since oxygen is one of the elements that most affects the mechanical properties of titanium alloys, the aim is to understand its influence on the machinability of these materials. To do so, two different oxygen contents of 1200 and 2000 ppm are tested. A comprehensive material characterisation of both materials is carried out in order to clearly establish their differences: chemical composition, microstructure and mechanical properties (yield strength and hardness of the phases by nanoindentation). Machining trials consist of (i) tool life tests, which include a tool wear analysis, and (ii) cutting fundamental turning tests, in which the cutting forces and the chip form are studied. The work concludes that Ti-6Al-4V alloy with the highest oxygen content has the worst machinability (~15 % lower compared to lowO), due to its higher volume fraction of β + α s phase, slightly harder α p and greater yield strength, which generates higher mechanical and thermal tool wear. Thus, oxygen is a key composition element that should be controlled in machining titanium alloys, if robust results in tool life are expected to be obtained. Nomenclature Symbol Description UnitsMaterial characterisation T β Beta-transus temperature (phase transition) ºC ε True strain () σ True stress MPa UTS Ultimate tensile strength MPa YS Yield stress MPa YS 0.2 Yield stress for a plastic deformation of 0.2 % MPa Machining tests E Activation energy J mol −1 V b Average flank wear mm α Clearance angle°A c Contact area on the rake face mm 2 Q Cooling flow l min −1 P Cooling pressure bar * Irantzu Sacristan isacristan@mondragon.edu;

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Experimental investigation on the effect of the material microstructure on tool wear when machining hard titanium alloys: Ti–6Al–4V and Ti-555

Cited by 98 publications

References 26 publications

On the Physics of Machining Titanium Alloys: Interactions between Cutting Parameters, Microstructure and Tool Wear

On the Physics of Machining Titanium Alloys: Interactions between Cutting Parameters, Microstructure and Tool Wear

Metallurgical and Machinability Characteristics of Wrought and Selective Laser Melted Ti-6Al-4V

Influence of oxygen content on the machinability of Ti-6Al-4V alloy

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