Tool wear mechanisms in axial ultrasonic vibration assisted milling in-situ TiB2/7050Al metal matrix composites

2020 ◽  
Vol 8 (2) ◽  
pp. 252-264
Author(s):  
Xiao-Fen Liu ◽  
Wen-Hu Wang ◽  
Rui-Song Jiang ◽  
Yi-Feng Xiong ◽  
Kun-Yang Lin
Materials ◽  
2020 ◽  
Vol 13 (21) ◽  
pp. 5011
Author(s):  
Cécile Escaich ◽  
Zhongde Shi ◽  
Luc Baron ◽  
Marek Balazinski

The TiC particles in titanium metal matrix composites (TiMMCs) make them difficult to machine. As a specific MMC, it is legitimate to wonder if the cutting mechanisms of TiMMCs are the same as or similar to those of MMCs. For this purpose, the tool wear mechanisms for turning, milling, and grinding are reviewed in this paper and compared with those for other MMCs. In addition, the chip formation and morphology, the material removal mechanism and surface quality are discussed for the different machining processes and examined thoroughly. Comparisons of the machining mechanisms between the TiMMCs and MMCs indicate that the findings for other MMCs should not be taken for granted for TiMMCs for the machining processes reviewed. The increase in cutting speed leads to a decrease in roughness value during grinding and an increase of the tool life during turning. Unconventional machining such as laser-assisted turning is effective to increase tool life. Under certain conditions, a “wear shield” was observed during the early stages of tool wear during turning, thereby increasing tool life considerably. The studies carried out on milling showed that the cutting parameters affecting surface roughness and tool wear are dependent on the tool material. The high temperatures and high shears that occur during machining lead to microstructural changes in the workpiece during grinding, and in the chips during turning. The adiabatic shear band (ASB) of the chips is the seat of the sub-grains’ formation. Finally, the cutting speed and lubrication influenced dust emission during turning but more studies are needed to validate this finding. For the milling or grinding, there are major areas to be considered for thoroughly understanding the machining behavior of TiMMCs (tool wear mechanisms, chip formation, dust emission, etc.).


2016 ◽  
Vol 86 (9-12) ◽  
pp. 3517-3526 ◽  
Author(s):  
Yifeng Xiong ◽  
Wenhu Wang ◽  
Ruisong Jiang ◽  
Kunyang Lin ◽  
Guodong Song

2021 ◽  
Author(s):  
Xiaofen Liu ◽  
Wenhu Wang ◽  
Ruisong Jiang ◽  
Yifeng Xiong ◽  
Kunyang Lin ◽  
...  

Abstract As a new method developed for machining difficult-to-cut materials, ultrasonic vibration-assisted machining technology has received increasing attention due to its superior properties in reducing cutting temperature in recent years. However, analytical models revealing the mechanism and predicting the cutting temperature for ultrasonic vibration-assisted machining are still needed to be developed. In this paper, an analytical model was established to predict the workpiece temperature for ultrasonic vibration-assisted milling of in-situ TiB2/Al-MMCs. The heat intensity would be directly determined by the cutting force which was significantly influenced by the ultrasonic vibration motion. Meanwhile, the moving heat source theory was applied for calculating dynamic heat flux and partition ratio. Besides, material properties, tool geometry, cutting parameters and vibration parameters were taken into account for workpiece temperature modeling. Finally, the developed analytical temperature model was validated by milling experiments with and without ultrasonic vibration on in-situ TiB2/7050Al metal matrix composites. The relative errors between model prediction results and experiments were smaller than 17%, indicating that the proposed model could provide workpiece temperature prediction reliability and accuracy. Furthermore, the established-analytical model could be used not only in ultrasonic vibration-assisted milling but also in conventional milling for the metal matrix composites.


2018 ◽  
Vol 60 (12) ◽  
pp. 1221-1224 ◽  
Author(s):  
Balachandran Gobalakrishnan ◽  
P. Ramadoss Lakshminarayanan ◽  
Raju Varahamoorthi

2019 ◽  
Vol 61 (8) ◽  
pp. 779-786
Author(s):  
Bellamballi Munivenkatappan Muthami Selvan ◽  
Veeramani Anandakrishnan ◽  
Muthukannan Duraiselvam ◽  
Sivaraj Sundarameenakshi

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