scholarly journals Influence of turning tool wear on the surface integrity and anti-fatigue behavior of Ti1023

2021 ◽  
Vol 13 (4) ◽  
pp. 168781402110112
Author(s):  
Li Xun ◽  
Wang Ziming ◽  
Yang Shenliang ◽  
Guo Zhiyuan ◽  
Zhou Yongxin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Plastic Deformation ◽  
Titanium Alloy ◽  
Fatigue Life ◽  
Tool Wear ◽  
Surface Integrity ◽  
Low Cycle Fatigue ◽  
Fatigue Behavior ◽  
Machined Surface ◽  
Deformation Layer

Titanium alloy Ti1023 is a typical difficult-to-cut material. Tool wear is easy to occur in machining Ti1023, which has a significant negative effect on surface integrity. Turning is one of the common methods to machine Ti1023 parts and machined surface integrity has a direct influence on the fatigue life of parts. To control surface integrity and improve anti-fatigue behavior of Ti1023 parts, it has an important significance to study the influence of tool wear on the surface integrity and fatigue life of Ti1023 in turning. Therefore, the effect of tool wear on the surface roughness, microhardness, residual stress, and plastic deformation layer of Ti1023 workpieces by turning and low-cycle fatigue tests were studied. Meanwhile, the influence mechanism of surface integrity on anti-fatigue behavior also was analyzed. The experimental results show that the change of surface roughness caused by worn tools has the most influence on anti-fatigue behavior when the tool wear VB is from 0.05 to 0.25 mm. On the other hand, the plastic deformation layer on the machined surface could properly improve the anti-fatigue behavior of specimens that were proved in the experiments. However, the higher surface roughness and significant surface defects on surface machined utilizing the worn tool with VB = 0.30 mm, which leads the anti-fatigue behavior of specimens to decrease sharply. Therefore, to ensure the anti-fatigue behavior of parts, the value of turning tool wear VB must be rigorously controlled under 0.30 mm during finishing machining of titanium alloy Ti1023.

Surface Integrity and Fatigue Property of a High Speed Milled Titanium Alloy

2008 ◽  
Vol 53-54 ◽  
pp. 305-310 ◽  
Author(s):  
Guo Sheng Geng ◽  
Jiu Hua Xu
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Titanium Alloy ◽  
Surface Integrity ◽  
Work Hardening ◽  
High Speed ◽  
Cutting Speed ◽  
Fatigue Property ◽  
Machined Surface ◽  
Metallurgical Structure

Surface integrity has a great effect on the fatigue property of titanium alloy. The surface integrity and fatigue property of a high speed milled Ti-6.5Al-2Zr-1Mo-1V (TA15) titanium alloy were investigated in this research. The main objective of this paper is to study the influence of milling speed on the surface integraty and fatigue property of the machined part. The surface roughness, work hardening, metallurgical structure and residual stress of the machined surface were studied in a cutting speed range of from 50m/min to 300m/min. To verify the relationship between cutting speed and the surface integrity of machined surface, the fatigue property of titanium alloy specimens milled at four different cutting speeds ranging from 50 to 200m/min were compared at two stress levels. This research shows that the cutting speed has little effect on the work hardening, metallurgical structure and residual stress, but the surface roughness decreases with the increasing cutting speed. Therefore, increasing milling speed has a positive effect on the surface integrity and fatigue property of the machined surface.

Influence of Cutting Parameters and Tool Wear on Martensitic Stainless Steel Surface Integrity After a Face Milling Process

2009 ◽  
Author(s):  
Patricia Mun˜oz de Escalona ◽  
Paul G. Maropoulos
Keyword(s):  
Surface Roughness ◽  
Stainless Steel ◽  
Tool Wear ◽  
Surface Integrity ◽  
Surface Finish ◽  
Cutting Tool ◽  
Fatigue Behavior ◽  
Cutting Speed ◽  
Stainless Steel Surface ◽  
Workpiece Material

Surface finish is one of the most relevant aspects of machining operations, since it is one of the principle methods to assess quality. Also, surface finish influences mechanical properties such as fatigue behavior, wear, corrosion, etc. The feed, the cutting speed, the cutting tool material, the workpiece material and the cutting tool wear are some of the most important factors that affects the surface roughness of the machined surface. Due to the importance of the martensitic 416 stainless steel in the petroleum industry, especially in valve parts and pump shafts, this material was selected to study the influence of the feed per tooth and cutting speed on tool wear and surface integrity. Also the influence of tool wear on surface roughness is analyzed. Results showed that high values of roughness are obtained when using low cutting speed and feed per tooth and by using these conditions tool wear decreases prolonging tool life.

Surface integrity generated with peripheral milling and the effect on low-cycle fatigue performance of aeronautic titanium alloy Ti-6Al-4V

2017 ◽  
Vol 122 (1248) ◽  
pp. 316-332 ◽  
Author(s):  
D. Yang ◽  
Z. Liu
Keyword(s):  
Residual Stress ◽  
Titanium Alloy ◽  
Fatigue Life ◽  
Stress Concentration ◽  
Surface Integrity ◽  
Stress Concentration Factor ◽  
Concentration Factor ◽  
Low Cycle Fatigue ◽  
Cycle Fatigue ◽  
Micro Hardness

ABSTRACTMachining-induced surface integrity has an important effect on reliability and service life of the components used in the aerospace industry where titanium alloy Ti-6Al-4V is widely applied. Characterisation of machining-induced surface integrity and revealing its effect on fatigue life are conducive to structural fatigue life optimisation design. In the present study, surface topography, residual stress, microstructure and micro-hardness were first characterised in peripheral milling of titanium alloy Ti-6Al-4V. Then, low-cycle fatigue performances of machined specimens were investigated on the basis of the tension-tension tests. Finally, the effects of surface integrity factors (stress concentration factor, residual stress and micro-hardness) on fatigue performances were discussed. Results show that stress concentration can reduce the fatigue life while increasing the residual compressive stress, and micro-hardness is beneficial to prolonging the fatigue life, but when the surface material of the specimen is subjected to plastic deformation due to yield, the residual stress on the surface is relaxed, and the effect on the fatigue performance is disappeared. Under the condition of residual stress relaxation, the stress concentration factor is the main factor to determine the low-cycle fatigue life of titanium alloy Ti-6Al-4V. While for the specimens with no residual stress relaxation, micro-hardness was the key factor to affect the fatigue life, followed by residual stress and stress concentration factor, respectively.

Effect of Drill Point Angle on Surface Integrity when Drilling Titanium Alloy

2013 ◽  
Vol 845 ◽  
pp. 966-970
Author(s):  
Muhamad Nasir Murad ◽  
Safian Sharif ◽  
E.A. Rahim ◽  
Rival
Keyword(s):  
Surface Roughness ◽  
Surface Integrity ◽  
Surface Microhardness ◽  
Machined Surface ◽  
Safety Requirements ◽  
Subsurface Deformation ◽  
Aerospace Applications ◽  
Average Hardness ◽  
Drill Point ◽  
Deformation Layer

Surface integrity of machined component is of major importance for the reliability and safety requirements during in service especially for the aerospace applications. This paper presents an investigation on the effect of drill geometry on the surface integrity of drilled hole of Ti-6AL-4V during drilling operation. Drilling experiments were conducted under the MQL using a special vegetable oil known as Jatropha oil. Experimental results revealed that drill point angle and coolant-lubricant conditions significantly influence the surface integrity which include surface roughness, micorhardness and microstructure defects. The surface roughness decreased with greater drill point angle. The subsurface deformation layer thickness was approximately 9 - 15 μm from the top of the machined surface. Microhardness profiles of the last hole indicated that the subsurface deformation extend up to a 150 to 200 μm until it reaches to the average hardness.

scholarly journals Effects of Machined Surface Integrity on High-Temperature Low-Cycle Fatigue Life and Process Parameters Optimization of Turning Superalloy Inconel 718

Materials ◽  
2021 ◽  
Vol 14 (9) ◽  
pp. 2428
Author(s):  
Xiaoping Ren ◽  
Zhanqiang Liu ◽  
Xiaoliang Liang ◽  
Pengcheng Cui
Keyword(s):  
Residual Stress ◽  
High Temperature ◽  
Fatigue Life ◽  
Process Parameters ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Low Cycle Fatigue ◽  
Cycle Fatigue ◽  
Machined Surface ◽  
Machined Surface Integrity

Machined surface integrity characteristics, including surface stresses, physical-mechanical properties and metallographic structures, play important roles in the fatigue performance of machined components. This work aimed at investigating the effects of machined surface integrity on high-temperature low-cycle fatigue life. The process parameters were optimized to obtain required surface integrity and fatigue life of the turning superalloy Inconel 718. The relationships between low-cycle fatigue life and machined surface integrity characterization parameters were established based on the low-cycle fatigue tests at a high temperature (650 °C). The sensitivities of turning process parameters to high-temperature low-cycle fatigue life were analyzed, and the optimization parameters were proposed with the goal of antifatigue manufacturing. Experimental results indicated that the impact order of the characterization parameters of machined surface integrity on the high-temperature low-cycle fatigue life were the degree of work hardening RHV, the residual stress in the cutting speed direction S22, the fatigue stress concentration factor Kf, the degree of grain refinement RD and the residual stress in the feed direction S33. In the range of turning parameters of the experiments in this research, the cutting speeds could be 80~110 m/min, and the feed rate could be 0.10~0.12 mm/rev to achieve a longer high-temperature low-cycle fatigue life. The results can be used for guiding the fatigue-resistant manufacturing research of aeroengine superalloy turbine disks.

scholarly journals Effects of Tool Wear on Machined Surface Integrity During Milling of Inconel 718

2021 ◽  
Author(s):  
Liang Tan ◽  
Changfeng Yao ◽  
Dinghua Zhang ◽  
Minchao Cui ◽  
Xuehong Shen
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Tool Wear ◽  
Surface Integrity ◽  
Inconel 718 ◽  
Flank Wear ◽  
Cutting Temperature ◽  
Machined Surface ◽  
Tool Flank Wear ◽  
Machined Surface Integrity

Abstract This paper investigates the effects of tool wear on the machined surface integrity characteristics, including the surface roughness, surface topography, residual stress, microhardness and microstructure, during ball-end milling of Inconel 718. Tool wear, tool lifetime, and cutting force are measured. In addition, a two-dimensional finite element-based model is developed to investigate the cutting temperature distribution in the chip–tool–workpiece contact area. Results show that the ball nose end mill achieves tool lifetime of approximately 350 min. The cutting forces increase sharply with a greater tool flank wear width, while the highest cutting temperature has a decreasing tend at a flank wear width of 0.3 mm. Higher tool flank wear width produces larger surface roughness and deteriorative surface topography. A high-amplitude (approximately −700 MPa) and deep layer (approximately 120 mm) of compressive residual stress are induced by a worn tool with 0.3 mm flank wear width. The surface microhardness induced by new tool is larger than that induced by worn tool. Plastic deformation and strain streamlines are observed within 10 mm depth beneath the surface. The results in this paper provide an optimal tool wear criterion which integrates the surface integrity requirements and the tool lifetime for ball-end finish milling of Inconel 718.

Experiment Study of Tool Wear and Surface Integrity in High Speed Milling of a New Damage-Tolerant Titanium Alloy

2012 ◽  
Vol 723 ◽  
pp. 177-181 ◽  
Author(s):  
Qi Shi ◽  
Yin Fei Yang ◽  
Ning He ◽  
Liang Li ◽  
Wei Zhao
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Surface Integrity ◽  
High Speed ◽  
White Layer ◽  
Cutting Tools ◽  
Machined Surface ◽  
High Speed Milling ◽  
Metallurgical Structure ◽  
Damage Tolerant

TC4-DT is a new damage-tolerant titanium alloy. In the paper, a series of experiments on tool wear and surface integrity in high speed milling of the alloy were carried out. The tool lives of different tool materials were studied and the wear mechanism of cutting tools was also investigated. Then surface integrity, including surface roughness, microhardness and metallurgical structure was studied and analyzed in high speed milling at different tool wear status. Results showed that K10 is the most suitable cutting tool after considering a combination of factors. And good surface integrity could be obtained in high speed milling of TC4-DT under all cutting situations. In addition, even with acutely worn stages, there has been no so-called serious hardening layer (or white layer) according to the study of microhardness and metallurgical structure beneath the machined surface.

Investigation of Surface Integrity in Conventional Grinding of Ti-6Al-4V

2010 ◽  
Vol 126-128 ◽  
pp. 899-904 ◽  
Author(s):  
Guo Giang Guo ◽  
Zhi Qiang Liu ◽  
Xiao Jiang Cai ◽  
Qing Long An ◽  
Ming Chen
Keyword(s):  
Residual Stress ◽  
Surface Roughness ◽  
Surface Integrity ◽  
Ground Surface ◽  
Surface Residual Stress ◽  
Machined Surface ◽  
Conventional Grinding ◽  
Metallurgical Structure ◽  
Mechanical Factors ◽  
Deformation Layer

This paper investigates the surface integrity of Ti-6Al-4V in conventional grinding using SiC abrasive, it includes surface roughness, surface topography, surface residual stress and metallurgical structure alteration. The experiment result indicated that grinding depth and feed rate have significant effect on surface roughness. Workpiece ground surface was free of crack, but severe plastic deformation layer and light burn appeared because of chemical reactions and mechanical factors. Ground surface was in a state of high tensile residual stress, thermal cycling of surface layer had the greatest effect. The machined surface experienced microstructure alteration on the top layer of ground surface, a heat-affected zone (HAZ) was observed.

scholarly journals The Surface Integrity of Titanium Alloy When Using Micro-Textured Ball-End Milling Cutters

Micromachines ◽  
2018 ◽  
Vol 10 (1) ◽  
pp. 21 ◽  
Author(s):  
Shucai Yang ◽  
Song Yu ◽  
Chunsheng He
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Surface Integrity ◽  
Work Hardening ◽  
End Milling ◽  
Orthogonal Experiment ◽  
Processing Efficiency ◽  
Machined Surface ◽  
Surface Machining ◽  
Ball End Milling

Processing certain kinds of micro-textures onto the surface of tools can improve their wear resistance, reduce the friction between them and machined surfaces, prolong their service life and improve their processing efficiency. When milling titanium alloy with ball-end milling cutters, the cutting force and the cutting heat causes plastic deformation and a concentration of stress on workpiece surfaces, damaging their surface integrity. In this paper, we report on a test involving the milling of titanium alloy, where a micro-texture was placed onto the front of a ball-end cutter and the surface roughness and work hardening of the machined surface were studied. The orthogonal experiment was designed around changes in the diameter of the micro-texture, its depth, the spacing between individual micro-pits, and its distance from the cutting edge. Data from the experiment was then used to assess the influence changes in the micro-texture parameters had upon the roughness and hardening of the surface. The data was processed and analyzed by using regression analysis and a prediction model for surface roughness and work hardening was established. The reliability of the model was then verified. The contents of this paper provide a theoretical basis for improving the cutting performance and the surface machining quality of cemented carbide tools.

Surface integrity and fatigue behavior in shot-peening for high-speed milled 7055 aluminum alloy

2016 ◽  
Vol 231 (2) ◽  
pp. 243-256 ◽  
Author(s):  
Changfeng Yao ◽  
Lufei Ma ◽  
Yongxia Du ◽  
Junxue Ren ◽  
Dinghua Zhang
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Fatigue Life ◽  
Compressive Stress ◽  
Surface Integrity ◽  
Shot Peening ◽  
High Speed ◽  
Fatigue Behavior ◽  
Source Zone ◽  
7055 Aluminum Alloy

The influence of shot-peening parameters on surface integrity of 7055 aluminum alloy is investigated based on shot-peening experiments. Surface integrity measurements, fatigue fracture analysis and fatigue life tests are conducted to reveal the effect of surface integrity on crack initiation and fatigue life. The results show that surface roughness increases significantly, and irregular pits and bumps appear on surface after shot-peening; grain on subsurface is refined and produces a shift and distortion in the pellets hit direction; compressive stress can be detected on all machined surfaces. Shot-peening parameters have significant impact on micro-hardness. In comparison with the milled specimen, fatigue life of peened specimens is improved by about 23.8, 3.96 and 1.01 times. Fatigue source zone transfers from stress concentration location on surface to subsurface due to the lower surface roughness and lager residual compressive stress.

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