Wear Mechanism and Modeling of Tribological Behavior of Polycrystalline Diamond Tools When Cutting Ti6Al4V

2018 ◽  
Vol 140 (12) ◽  
Author(s):  
Guangxian Li ◽  
Shuang Yi ◽  
Cuie Wen ◽  
Songlin Ding
Keyword(s):  
Transition Zone ◽  
Wear Mechanisms ◽  
Tribological Behavior ◽  
Theoretical Calculations ◽  
Cutting Speed ◽  
Polycrystalline Diamond ◽  
Analytical Models ◽  
Workpiece Material ◽  
Pcd Tools ◽  
Sliding Zone

Owing to its outstanding physical and mechanical properties, polycrystalline diamond (PCD) is ideal for cutting titanium alloys. However, the high temperature and stress caused by the interaction of tool surface and chip flow lead to different types of wear. This paper investigates the wear mechanisms of PCD tools in three different tribological regions: sticking zone, transition zone, and sliding zone, when machining titanium alloy Ti6Al4V. The tribological behavior of PCD tools in the wear processes were analyzed through both experiments and theoretical calculations. Analytical models of stresses and temperature distribution were developed and validated by turning experiments. PCD tools, consisting of diamond grains of different sizes: CTB002 (2 μm), CTB010 (10 μm), and CTM302 (2–30 μm), were used to cut Ti6Al4V at the normal cutting speed of 160 m/min and high cutting speed 240 m/min. It was found that adhesion, abrasion and diffusion dominated the wear process of PCD tools in different worn regions. Microscopic characters showed that the wear mechanisms were different in the three tribological regions, which was affected by the distribution of stresses and temperature. “Sticking” of workpiece material was obvious on the cutting edge, abrasion was severe in the transition zone, and adhesion was significant in the sliding zone. The shapes and morphological characters in different worn regions were affected by the stresses distribution and the types of PCD materials.

Experimental Investigation on Surface Roughness in Precision Cutting Ti6Al4V Alloy Using Diamond Tools

2014 ◽  
Vol 800-801 ◽  
pp. 576-579
Author(s):  
Lin Hua Hu ◽  
Ming Zhou ◽  
Yu Liang Zhang
Keyword(s):  
Surface Roughness ◽  
Cutting Speed ◽  
Polycrystalline Diamond ◽  
Cutting Parameters ◽  
Limited Range ◽  
Nose Radius ◽  
Machined Surface ◽  
Machined Surface Roughness ◽  
Titanium Alloy Ti6al4v ◽  
Pcd Tools

In this work, cutting experiments were carried out on titanium alloy Ti6Al4V by using polycrystalline diamond (PCD) tools to investigate the effects of the tool geometries and cutting parameters on machined surface roughness. Experimental results show machined surface roughness decreases with increases in the flank angle, tool nose radius and cutting speed within a limited range respectively, and begins to increase as the factors reaches to certain values respectively. And machined surface roughness decreases with increases in feed rate and cutting depth respectively.

Phase Dependent Tool Wear in Turning Ti-6Al-4V Using Polycrystalline Diamond and Carbide Inserts

2014 ◽  
Vol 136 (4) ◽  
Author(s):  
David J. Schrock ◽  
Di Kang ◽  
Thomas R. Bieler ◽  
Patrick Kwon
Keyword(s):  
Phase Transformation ◽  
Tool Wear ◽  
Cutting Speed ◽  
Polycrystalline Diamond ◽  
Alpha Phase ◽  
Laser Scanning Microscopy ◽  
Phase Transformation Temperature ◽  
Rake Face ◽  
Work Material ◽  
Pcd Tools

Tool wear of polycrystalline diamond inserts was analyzed in turning experiments on Ti-6Al-4V. Evidence of phase transformation in turning titanium work material is presented and its impact on tool wear is discussed. Confocal laser scanning microscopy was used to analyze the rake face of the turning inserts. At cutting speed of 61 m/min, the rake face exhibited scalloped-shaped, fractured wear, characteristic of typical attrition wear. At cutting speed of 122 m/min, a smooth crater was observed, which is a typical characteristic of diffusion/dissolution wear. At the cutting speed of 91 m/min, the wear features were a combination of those observed at speeds of 61 m/min and 122 m/min. A comparison of the wear on the polycrystalline diamond (PCD) tools to that of WC-6Co from our earlier work is also discussed. Microstructural analysis of the of both the undeformed work material and the chip using electron-backscatter diffraction provided evidence to support the phase transformation. Temperature estimates on the rake face of the tool previously extracted from Finite Element Method (FEM) support the possibility of phase transformation at the high cutting speed tested. The difference in the wear pattern was also linked to the extent of recrystallization in the titanium work material. At 61 m/min there was more alpha phase in the work material without much recrystallization, which generated uneven scalloped wear. At 122 m/min, phase transformation of the existing alpha phase to the beta phase in the work material and recrystallization increased the dissolution/diffusion wear process.

Predictive Modeling and Optimization of High Performance Machining

2007 ◽  
Vol 10-12 ◽  
pp. 842-849
Author(s):  
Steven Y. Liang ◽  
Binti M. Abraham
Keyword(s):  
Tool Life ◽  
Process Parameters ◽  
High Performance ◽  
Manufacturing Systems ◽  
Cutting Speed ◽  
Cutting Fluid ◽  
Analytical Models ◽  
Machining Performance ◽  
Machining Processes ◽  
Workpiece Material

High performance machining refers to the material removal operation that delivers the maximum achievable part quality, process competitiveness, and ecological compatibility through strategic utilization of cutters, machine tools, operation configuration, and process parameters. It is rapidly emerging as a prerequisite to productivity and profitability of machining operations and associated manufacturing systems. To accomplish high performance machining, a thorough understanding of the underlying mechanics that affect the performance attributes such as tool life, part integrity, air quality, etc., and how it is attributed to tooling conditions, operation configuration, and process parameters, is required. This paper reviews and summarizes a series of analytical methodologies by coupling with studies performed at the Georgia Institute of Technology for the quantitative modeling of fundamental mechanics of machining in the context of thermal, mechanical, tribological, and metallurgical effects and their interactions. In this study, cutting stresses, residual stress and tool life are explicitly described as functions of tool geometries, cutting speed, chip load, cutting fluid properties, interface tribological conditions, and the cutter/workpiece material constants. These analytical models facilitate the prediction of machining performance thereby allowing the optimal planning of machining processes in pursuing maximum performance. An array of experimental cutting data is also presented in comparison to model-based predictions for the validation of all aspects of the machining mechanics analysis.

Study on the Wear Mechanism of PCD Tools in High-Speed Milling of Al-Si Alloy

2011 ◽  
Vol 381 ◽  
pp. 16-19 ◽  
Author(s):  
Yong Guo Wang ◽  
Biao Liu ◽  
Jiong Yi Song ◽  
Xiang Ping Yan ◽  
Kang Mei Wu
Keyword(s):  
Wear Mechanism ◽  
High Speed ◽  
Energy Dispersive Spectrometer ◽  
Cutting Speed ◽  
Polycrystalline Diamond ◽  
Machining Process ◽  
Diffusion Wear ◽  
Milling Tool ◽  
Pcd Tools ◽  
And Diffusion

Polycrystalline diamond (PCD) tools have been obtained increasing application in aluminum alloy processing industry due to the excellent surface finish and tool life comparing with other traditional tools. Investigation of the wear mechanism of PCD milling tool for machining Al-Si alloy at cutting speed of 5000m/min (n=12732r/min) has been performed. The wear morphology of tool has been studied by scanning electron microscopy (SEM) and energy dispersive spectrometer (EDS). Results show that PCD milling tool suffers from abrasive wear and diffusion wear on the flank face and adhesive wear on the rake face in the machining process.

Wear mechanisms of TiN-coated CBN tool during finish hard turning of hot tool die steel

2009 ◽  
Vol 224 (4) ◽  
pp. 553-566 ◽  
Author(s):  
J S Dureja ◽  
V K Gupta ◽  
V S Sharma ◽  
M Dogra
Keyword(s):  
Wear Rate ◽  
Feed Rate ◽  
Wear Mechanisms ◽  
High Speed ◽  
Hard Turning ◽  
Flank Wear ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Workpiece Material ◽  
Die Steel

The aim of the present investigation was to identify the wear mechanisms of TiN-coated CBN tools prevalent under different machining conditions during hard turning of hot tool die steel. The different wear mechanisms observed were abrasion wear at low cutting speed, low feed rate, and high workpiece hardness; formation of a transferred layer resulting from tribochemical reactions between constituents of the tool and workpiece material at high speed; and the formation of built-up edges at moderate cutting speed. Hard carbide particles of the work material at higher feed rate severely abraded the tool flank land, resulting in shallow grooves due to the detachment of CBN grains. At greater depth of cut, the built-up edges and transferred layer reduced friction and tool wear. Excessive adhesion of workpiece material followed by plastic deformation and notching were clearly visible at low workpiece hardness (47 HRC). The influence of cutting speed, feed rate, depth of cut, and workpiece hardness on the progressive tool flank wear, i.e. flank wear rate (VBr, μm/mm) in the steady wear region, was also analysed. The flank wear rate was observed to decrease with increase in cutting speed, depth of cut, and workpiece hardness, but after an initial decrease it increased with increase in feed rate.

Performance of Cutting Tools in High Speed Milling of SiCp/Al Composites

2012 ◽  
Vol 591-593 ◽  
pp. 311-314 ◽  
Author(s):  
Yang Jun Wang ◽  
Ming Qiang Pan ◽  
Tao Chen ◽  
Ji Zhu Liu ◽  
Li Guo Chen
Keyword(s):  
High Speed ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Chemical Vapor ◽  
Polycrystalline Diamond ◽  
Cvd Diamond ◽  
Optical Microscope ◽  
Coated Tools ◽  
Tools Wear ◽  
Pcd Tools

This paper presents an experimental study in milling of SiCp/Al composites on a high precision machine by using chemical vapor deposition(CVD) diamond coated tools and polycrystalline diamond (PCD) tools. The tool wear was observed and measured by an optical microscope and a scanning electron microscope (SEM). The results show that the coating rupture causes the failure of the CVD diamond coated tools. The PCD tools’ wear is less. At the relatively low cutting speed, the wear pattern of PCD tools is the flank wear which caused by the abrasion of SiC particles. Due to the low cutting temperature, the graphitization of PCD tools does not happen. The wear mechanism of PCD tools will be the abrasive and adhesive wear.

Wear Behaviors of PCD Tools in Turning Granite

2011 ◽  
Vol 337 ◽  
pp. 728-734 ◽  
Author(s):  
Rui Zhang ◽  
Zi Li Kou ◽  
Yun Wei Dou ◽  
Shen Zhuo Liu ◽  
Hai Kuo Wang ◽  
...  
Keyword(s):  
Electron Microscopy ◽  
Wear Mechanisms ◽  
Cutting Tools ◽  
Polycrystalline Diamond ◽  
Test Method ◽  
Tool Performance ◽  
Thermal Wear ◽  
Pcd Tools ◽  
Cutting Speeds ◽  
Scanning Electron

The performance and wear mechanisms of two types of polycrystalline diamond (PCD) cutting tools (marked as PCD 010 and PCD 030) have been investigated in this paper. Continuous turning of round granite bars has been selected as the test method. The Taylor equation has been developed to describe the tool performance. The experimental results indicate that PCD 010 has a greater thermal wear resistance than PCD 030 at high cutting speeds. Scanning electron microscopy (SEM) was used to evaluate wear mechanisms of PCD tools, our results show that the dominant wear mechanisms for PCD 010 is abrasion wear while that for PCD 030 is inter-granular and cleavage wear.

Experimental Study on Turning of Titanium Matrix Composites with PCD Tools

2012 ◽  
Vol 723 ◽  
pp. 20-24 ◽  
Author(s):  
Hai Xiang Huan ◽  
Jiu Hua Xu ◽  
Yu Can Fu ◽  
Hong Hua Su ◽  
Wei Liang Bian ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Tool Life ◽  
Mechanical Performance ◽  
Cutting Speed ◽  
Polycrystalline Diamond ◽  
Matrix Composites ◽  
Titanium Matrix ◽  
Titanium Matrix Composites ◽  
Workpiece Surface ◽  
Pcd Tools

Titanium Matrix Composites (TMCs) parts usually requires high mechanical performance. The good workpiece surface quality and long tool life is the two target of finishing machining. In this paper, finishing turning tests are performed to investigate the workpiece surface roughness and tool life of machining TMCs with Polycrystalline Diamond (PCD) tools at the cutting speed range 60m/min to 120m/min. The results show that the workpiece surface roughness is obtained range Ra 0.44 to Ra 0.53m. tool life reaches about 10.6min, 7.9min, 7min and 5.5min at the cutting speed of 60m/min, 80m/min, 100m/min and 120m/min, respectively.

Study on Wear Behaviors and Grain Effects of PCD Cutting Tools in Turning Granite

2012 ◽  
Vol 214 ◽  
pp. 130-135
Author(s):  
Shen Zhuo Liu ◽  
Zi Li Kou ◽  
Rui Zhang ◽  
Cheng Liang Liu ◽  
Yu Li ◽  
...  
Keyword(s):  
Grain Size ◽  
Abrasive Wear ◽  
Optical Microscopy ◽  
Wear Mechanism ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Polycrystalline Diamond ◽  
Wear Volume ◽  
Average Grain Size ◽  
Pcd Tools

In this paper, three types of polycrystalline diamond (PCD) tools marked as PCD 030, PCD 010 and PCD 005 (equivalent to 30, 10, and 5μm average grain size of original diamond) were tested, and their wear behaviors was studied. The wear of PCD cutting tools in machining granite bars was invested by a turning process. The experiments were carried out under wet condition. Wear volume was measured by optical microscopy and wear morphology was examined by scanning election microscopy (SEM) and optical microscopy. By comparing the flank face, the experiments results show that the PCD tools with coarse original diamond grain size have long life at three cutting speeds, and the tool life of the three PCD tools decreases with the increase of cutting speed. SEM morphology by secondary electron image analysis indicates that the dominant wear mechanism for PCD 010 and PCD 005 is abrasive wear. While for PCD 030, the abrasive wear mechanism is predominant wear in the machining, occasionally some cleavage wear are also observed.

Influence of cutting speed and workpiece material on the wear mechanisms of CVD TiCN/α-Al2O3 coated cutting inserts during turning

Wear ◽  
2018 ◽  
Vol 398-399 ◽  
pp. 90-98 ◽  
Author(s):  
Martina Gassner ◽  
Nina Schalk ◽  
Michael Tkadletz ◽  
Markus Pohler ◽  
Christoph Czettl ◽  
...  
Keyword(s):  
Wear Mechanisms ◽  
Cutting Speed ◽  
Workpiece Material ◽  
Cutting Inserts ◽  
Α Al2o3
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