Influence of the machining parameters and cooling strategies on the wear behavior of wrought and additive manufactured Ti6Al4V for biomedical applications

Bruschi, Stefania; Bordin, Alberto; Medea, Francesco; Ghiotti, Andrea

doi:10.1016/j.triboint.2016.05.036

Cited by 70 publications

(28 citation statements)

References 20 publications

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“…In addition to this, it was confirmed by numerous studies that cryogenic machining not only does substantially increase the machinability of hard-to-cut materials but also does improve the obtainable surface integrity [17,19,[24][25][26][27]. Lower roughness values could be achieved in comparison to emulsion cooling and dry machining [27].…”

Section: Introductionmentioning

confidence: 68%

“…In general, lower roughness values were measured if cryogenic cooling was applied in comparison to dry machining, even though this observation is not statistically significant. Several authors have reported an improvement in surface integrity by means of cryogenic cooling in comparison to conventional machining concepts [17,19,[24][25][26][27]. It is therefore conceivable that cryogenic milling also resulted in better surface qualities here.…”

Section: Surface Roughnessmentioning

confidence: 99%

“…Lower roughness values could be achieved in comparison to emulsion cooling and dry machining [27]. Furthermore, the considerable cooling effect results in a rise in micro-hardness and compressive stresses in the outer layer of the workpiece, thus frequently leading to an enhanced wear resistance [25]. Positive effects on fatigue behavior and corrosion resistance were also reported [17,26,28].…”

Section: Introductionmentioning

confidence: 97%

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Hybrid manufacturing of titanium Ti-6Al-4V combining laser metal deposition and cryogenic milling

Moritz

Seidel

Kopper

et al. 2020

Int J Adv Manuf Technol

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Hybrid manufacturing, which, e.g., combines additive manufacturing with conventional machining processes, can be a way of overcoming limitations currently encountered in additive manufacturing. Cryogenic milling might be a viable option for hard-tocut materials, as it leaves a contamination-free surface and can increase surface quality and tool life compared to conventional cooling concepts. In this study, the influence of cryogenic milling with carbon dioxide on titanium Ti-6Al-4V specimens manufactured with laser metal deposition (LMD) was investigated regarding tool wear and surface integrity in comparison to dry machining and machining with cooling lubricants. Moreover, additional layers of material were deposited on top of conventionally and cryogenically machined surfaces by means of LMD. The interface zone was then examined for defects. The milling process was closely monitored by means of thermal and high-speed imaging. Optical and tactile surface analysis provided evidence that lower roughness values and improved surface qualities could be obtained with cryogenic machining in comparison to dry machining. Moreover, significantly less tool wear was observed when a cryogenic cooling medium was applied. Although the utilization of conventional cooling lubricants resulted in satisfying surface qualities, substantial residual contamination on the milled surface was detected by means of fluorescence analysis. These contaminants are suspected to cause defects when the next layer of material is deposited. This is supported by the fact that pores were found in the weld bead applied on top of the milled specimens by means of LMD. Conversely, cryogenic machining resulted in very clean surfaces due to the residue-free evaporation of the coolant. Hence, a good metallurgical bonding between the weld bead and the milled substrate could be achieved. The results indicate the great potential of cryogenic milling in hybrid manufacturing, especially in terms of intermediate machining, as it provides residue-free surfaces for subsequent material deposition without an additional cleaning step and can significantly prolongate tool life.

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Section: Introductionmentioning

confidence: 68%

Section: Surface Roughnessmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 97%

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Hybrid manufacturing of titanium Ti-6Al-4V combining laser metal deposition and cryogenic milling

Moritz

Seidel

Kopper

et al. 2020

Int J Adv Manuf Technol

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“…Orthopedic implants, in contrast to a transplant which are biological products, are humanmade products. The surface of implants which comes in contact with the live tissues, cells or blood should be essentially made of a biomedical metal such as titanium or titanium alloy for eradication of rejection or infection [2,21,22]. Titanium has acceptable mechanical properties and has been used for orthopedic implants, yet for still better performance titanium is alloyed with small amounts of aluminium and vanadium (Ti-6Al-4V), typically 6% and 4% respectively, by weight [3,23,24].…”

Section: Introductionmentioning

confidence: 99%

Sustainability in bio-metallic orthopedic implants

2019

Biointerface Res Appl Chem

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An orthopedic implant is surgically introduced into the body as a replacement of a missing or affected biological structure. As these are stationed inside the body hence the material chosen should be bio-acceptable so that it does not cause rejection or gangrene. In this work, Ti-6Al-4V has been chosen for the implant. In actual practice the implant, after design approval is cast and machined to the required dimension and surface smoothness followed by heat treatment to remove stresses induced while machining. The product needs to be cooled before surgical fitment. The present work proposes film cooling technique for the same. The primary deciding factor for the effectiveness and longevity of the orthopedic implants primarily concentrates on the cooling effectiveness. The simulation study has been done using Fluid Flow Simulator Analysis software i.e. FLUENT and results were found to be in good agreement with the experimental results available in the relevant literature. The present work was aimed at a critical situation where an orthopedic implant of titanium alloy (Ti-6Al-4V) is to be manufactured ensuring that it not only resists loosening or migration but also is thermally stable and does not damage surrounding tissues or organs. The results indicate that although forward injection of coolant is a more economically viable but backward injection of coolant should be preferred while working with an orthopedic implant as it provides more area under cooling. Hence it can be inferred that with a backward injected cooling system the implant would be cooled better and would surely ensure a better component with respect to strength and longevity.

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“…Extensive research has been conducted to investigate the surface integrity of Inconel 718 under dry and flood cooling environments. 16,17 The purpose of the present study is to optimise the cutting parameters including cutting fluid conditions to yield the desired surface integrity. Orthogonal HPJAM of Inconel 718 is conducted by using an Al 2 O 3 PVD-coated carbide tool with both rake and flank injection tool holder.…”

Section: Introductionmentioning

confidence: 99%

Influences of cutting fluid conditions and cutting parameters on surface integrity of Inconel 718 under high‐pressure jet–assisted machining (HPJAM)

Mohsan

Wang

Ren

et al. 2018

Lubrication Science

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Cutting fluids are widely used in machining processes for cooling and lubricating the tool and workpiece interface to enhance machinability. However, the generation of machined surface under cutting fluid conditions is more complex than that under dry cutting conditions. In this study, orthogonal turning of the difficult‐to‐machine Inconel 718 alloy is conducted under dry and high‐pressure jet–assisted machining, respectively. The machining parameters and coolant conditions are investigated to optimise the surface integrity. Machining forces, microhardness, profile, and areal surface topography are analysed. Results show that a higher cutting speed of 140 m/min and a coolant pressure of 150 to 200 bar are the optimums to produce a satisfactory machined surface. High‐pressure coolant in cutting processes can lower the formation of surface deformities, improve surface integrity, and increase productivity. At a higher cutting speed and optimum coolant pressure, cutting forces are decreased, and the surface hardness as well as depth of the machining‐affected zone is depleted.

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Influence of the machining parameters and cooling strategies on the wear behavior of wrought and additive manufactured Ti6Al4V for biomedical applications

Cited by 70 publications

References 20 publications

Hybrid manufacturing of titanium Ti-6Al-4V combining laser metal deposition and cryogenic milling

Hybrid manufacturing of titanium Ti-6Al-4V combining laser metal deposition and cryogenic milling

Sustainability in bio-metallic orthopedic implants

Influences of cutting fluid conditions and cutting parameters on surface integrity of Inconel 718 under high‐pressure jet–assisted machining (HPJAM)

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