scholarly journals Experimental Study of Wear Mechanisms of Cemented Carbide in the Turning of Ti6Al4V

Materials ◽  
2019 ◽  
Vol 12 (17) ◽  
pp. 2822 ◽  
Author(s):  
Sara Saketi ◽  
Stina Odelros ◽  
Jonas Östby ◽  
Mikael Olsson
Keyword(s):  
High Resolution ◽  
Wear Mechanism ◽  
Elevated Temperatures ◽  
Flank Wear ◽  
Chemical Reactivity ◽  
High Strength ◽  
Cemented Carbide ◽  
Diffusion Wear ◽  
Carbide Inserts ◽  
Cutting Speeds

Titanium and titanium alloys such as Ti-6Al-4V are generally considered as difficult-to-machine materials. This is mainly due to their high chemical reactivity, poor thermal conductivity, and high strength, which is maintained at elevated temperatures. As a result, the cutting tool is exposed to rather extreme contact conditions resulting in plastic deformation and wear. In the present work, the mechanisms behind the crater and flank wear of uncoated cemented carbide inserts in the turning of Ti6Al4V are characterized using high-resolution scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and high-resolution Auger electron spectroscopy (AES).The results show that, for combinations of low cutting speeds and feeds, crater and flank wear were found to be controlled by an attrition wear mechanism, while for combinations of medium to high cutting speeds and feeds, a diffusion wear mechanism was found to control the wear. For the latter combinations, high-resolution SEM and AES analysis reveal the formation of an approximately 100 nm thick carbon-depleted tungsten carbide (WC)-layer at the cemented carbide/Ti6Al4V interface due to the diffusion of carbon into the adhered build-up layers of work material on the rake and flank surfaces.

Diffusion Behavior and Wear Mechanism of WC/Co Tools when Machining of Titanium Alloy

2018 ◽  
Vol 279 ◽  
pp. 60-66
Author(s):  
Da Shan Bai ◽  
Jian Fei Sun ◽  
Kai Wang ◽  
Wu Yi Chen
Keyword(s):  
Diffusion Layer ◽  
Wear Mechanism ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Diffusion Behavior ◽  
Fine Grain ◽  
Diffusion Wear ◽  
Material Forming ◽  
Wear Modes ◽  
Cutting Speeds

In this paper, fine-grain WC/Co tools were utilized in dry turning of the Ti-6Al-4V alloy. The wear modes of the cutting tools at different cutting speeds were analyzed. The diffusion behavior between the cutting tool and the workpiece was studied in detail based on the Auger electron spectroscopy (AES) depth profile technology. The diffusion wear mechanism was revealed. The results showed that the diffusion layer formed at the interface between the cutting tool and the adhering material. The diffusion ability of C was the strongest, followed by W, the weakest was Co in all the elements of the cutting tool. The chemical reactions took place close to the adhering material, forming the reaction layer. As a diffusion barrier, it was possible to limit the elements diffusion from the cutting tool to the adhering material, decrease the changes in the cutting tool composition and damages. The diffusion layer, which was weakened by diffusion, was worn off and taken away by the fast flowing chip during the cutting process, causing the diffusion wear characterized by a smooth crater formation on the tool surface.

An Experimental Investigation Into the High Speed Turning of Ti-6Al-4V Titanium Alloy

2010 ◽  
Author(s):  
Anil K. Srivastava ◽  
Jon Iverson
Keyword(s):  
Titanium Alloy ◽  
Titanium Alloys ◽  
High Speed ◽  
Elevated Temperatures ◽  
Chemical Reactivity ◽  
Specific Strength ◽  
Aerospace Applications ◽  
Layered Coatings ◽  
High Specific Strength ◽  
Cutting Speeds

Titanium and its alloys have seen increased utilization in military and aerospace applications due to combination of high specific strength, toughness, corrosion resistance, elevated-temperature performance and compatibility with polymer composite materials. Titanium alloys are difficult to machine due to their inherent low thermal conductivity and higher chemical reactivity with other materials at elevated temperatures. In general, temperature related machining difficulties are encountered at production speeds in the range of 60 m/min and high-speed machining of these alloys has created considerable interest to researchers, tool manufacturers and end users. This paper provides recent results obtained during turning operation with the aim of improving machinability of titanium alloys. Several tests have been conducted using (i) micro-edge prep geometry of the inserts, (ii) ultra-hard PVD coated, and (iii) nano-layered coated inserts and the effects of speeds and feeds during turning of Ti-6Al-4V titanium alloy are discussed. The initial tests have been conducted under orthogonal (2-D) cutting conditions with no coolant application. Based on these results, several oblique cutting (3-D) tests have been designed and conducted to study the effect of various types of ultra-hard and nano-layered coatings at higher cutting speeds under flooded coolant conditions. The effects of speed and feed on cutting force and tool wear are presented in this paper.

The Effect of Grain Size and Cobalt Content on the Wear of Ultrafine Cemented Carbide Tools

2014 ◽  
Vol 875-877 ◽  
pp. 1344-1351
Author(s):  
Jian Bing Cheng ◽  
Si Qin Pang ◽  
Xi Bin Wang ◽  
Xi Bin Wang ◽  
Chen Guang Lin
Keyword(s):  
Grain Size ◽  
Tool Wear ◽  
Tool Life ◽  
Wear Mechanism ◽  
Wear Mechanisms ◽  
High Strength Steels ◽  
Cobalt Content ◽  
Cemented Carbide ◽  
Cemented Carbide Tools ◽  
Cutting Speeds

This work contributes to a better understanding of wear mechanisms of ultrafine cemented carbide cutting tools used in turning operation of superalloy and high strength steels at high cutting speeds. The main objective of this work is to verify the influence of grain size and the cobalt content of ultrafine cemented carbide tools on tool life and tool wear mechanism. The main conclusions are that grain size and the cobalt content of ultrafine cemented carbide tools strongly influence tool life and tool wear involve different mechanisms. The wear mechanisms of different grain size and the cobalt content of ultrafine cemented carbide tools observed on the rake face at these conditions were adhesion and notch, at the end of tool life, adhesion was the main wear mechanism at higher cutting speeds.

Adhering failure and optimization of cemented carbide inserts for the heavy-duty cutting of high-strength steel forgings

2016 ◽  
Vol 231 (5) ◽  
pp. 930-938 ◽  
Author(s):  
Li Liu ◽  
Yao-Nan Cheng ◽  
Tong Wang ◽  
Geng-Huang He
Keyword(s):  
High Strength Steel ◽  
Large Scale ◽  
Cutting Temperature ◽  
High Strength ◽  
Cemented Carbide ◽  
Material Structure ◽  
High Temperature Strength ◽  
Heavy Duty ◽  
Carbide Inserts ◽  
Cemented Carbide Inserts

In this study, the adhering failure of cemented carbide inserts during the heavy-duty cutting of large-scale, high-strength steel forgings is investigated. First, the heavy-duty cutting of high-strength steel forgings is simulated. According to the results, the maximum cutting temperature and force were approximately 950 ℃ and 42 KN, respectively. Next, the effects of these thermal-mechanical loading conditions on the material performance of the inserts are discussed. In addition, the adhering failure of the inserts is analyzed. Then, an insert-chip adhering model and the high-temperature strength of the insert material are used to illustrate the critical condition of the insert-chip adhering process via MATLAB simulations. Furthermore, the anti-adhering performance of the inserts is improved and an optimized insert design for the heavy-duty cutting process is constructed from the aspects of insert material, structure and coating. According to the results, the service lift of the heavy-duty cutting inserts XF8 was two times greater than that of conventional welded cemented carbide inserts. The cutting parameters of the large-scale forging process are also optimized using the orthogonal experimental method. The results of this study could be used to improve the anti-adhering performance, service life, and production efficiency of cemented carbide inserts intended for the cutting of large-scale forgings.

Influence of Hydrogen Contents of Ti-6Al-4V Alloy on Friction and Wear Mechanism between Titanium Alloy and Cemented Carbide

2013 ◽  
Vol 584 ◽  
pp. 34-37
Author(s):  
Wei Hua Wei ◽  
Jiu Hua Xu ◽  
Yu Can Fu
Keyword(s):  
Chemical Reaction ◽  
Wear Mechanism ◽  
Wear Mechanisms ◽  
Friction And Wear ◽  
Sliding Friction ◽  
Energy Dispersive Spectrometer ◽  
Cemented Carbide ◽  
Special Device ◽  
Treatment Technology ◽  
Diffusion Wear

Ti-6Al-4V alloy was hydrogenated at 800°C by thermohydrogen treatment technology. Sliding friction and wear tests were carried out in a special device assembled on CA6140 turning lathe to investigate the friction and wear mechanism between hydrogenated titanium alloys and WC-Co cemented carbide. The morphological analyses of the worn surface were made by scanning electron microscope (SEM) and the diffusion and chemical reaction behavior of elements were analyzed by X-ray energy dispersive spectrometer (EDS). It was found that the main wear mechanisms of the unhydrogenated alloys were abrasion and adhesion and surface fatigue, while the main wear mechanisms of the hydrogenated alloys were abrasion and adhesion. The main wear mechanisms of the cemented carbide were all serious adhesion and spalling, and the specific wear forms were closed related to hydrogen contents. There are all not the chemical reaction wear and element diffusion wear in the friction region of whether the unhydrogenated alloys or the hydrogenated alloys or cemented carbide.

scholarly journals PERFORMANCE OF COATED CUTTING TOOLS IN MACHINING: A REVIEW

2020 ◽  
Author(s):  
Rukmini Srikant Revuru ◽  
Vamsi Krishna Pasam ◽  
Nageswara Rao Posinasetti
Keyword(s):  
High Temperatures ◽  
Elevated Temperatures ◽  
Materials Science ◽  
Cutting Tools ◽  
High Strength ◽  
Premature Failure ◽  
Aerospace Applications ◽  
Coated Tools ◽  
Intermediate Layers ◽  
Carbide Inserts

Rapid advances in materials science have prompted the development of materials and alloys of enhanced properties like high strength, hardness, etc. Though these alloys are beneficial in their applications, their machining is difficult. For instance, Inconel 718, a nickel-based alloy, is used in several aerospace applications. This alloy can retain its strength at high temperatures up to 750℃. However, machining Inconel is a problem due to its poor machinability. Similarly, titanium alloys are not very hard but react with tools at high temperatures and lead to their premature failure. Carbide inserts are commonly used as cutting tools in the industry. Carbide tools are manufactured using powder metallurgy technique and possess high strength and hardness, even at elevated temperatures. However, these tools are not effective in machining of “difficult-to-machine” materials and have very short life. In light of this, coated tools have evolved. The cutting tools are coated using very hard, non-reacting material and sometimes a solid lubricant. The coatings are made usually by using PVD or CVD techniques. Often, intermediate layers are provided to improve adhesion between the substrate and the actual coating. Coated tools have better resistance to temperatures and hence, better tool life compared to the regular cutting tools. This paper deals with the evolution of the technology of coated tools. Different types of coatings, their advantages/limitations and efficacy of coated tools in machining are reviewed and discussed.

The influence of ultrasonic elliptical vibration amplitude on cutting tool flank wear

2020 ◽  
Vol 234 (12) ◽  
pp. 1499-1512 ◽  
Author(s):  
Mohsen Khajehzadeh ◽  
Omid Boostanipour ◽  
Soheil Amiri ◽  
Mohammad Reza Razfar
Keyword(s):  
Wear Mechanism ◽  
Vibration Amplitude ◽  
Cutting Tool ◽  
Flank Wear ◽  
Ultrasonic Vibrations ◽  
Tool Flank Wear ◽  
Elliptical Vibration ◽  
Diffusion Wear ◽  
Ultrasonic Assisted ◽  
Ultrasonic Elliptical Vibration

In this article, the effect of vibration amplitude during ultrasonic elliptical vibration–assisted turning on cutting tool flank wear ( VBmax) and tool diffusion wear mechanism has been experimentally studied in machining of AISI 4140 hardened steel. To achieve this goal, an ultrasonic elliptical vibration–assisted turning setup was designed and manufactured. This device was then used in both ultrasonic-assisted tuning and ultrasonic elliptical vibration–assisted turning tests (i.e. one-dimensional and two-dimensional ultrasonic-assisted machining). According to the achieved results, ultrasonic elliptical vibration–assisted turning is more effective than ultrasonic-assisted tuning in reducing tool flank wear; at an amplitude of 13 μm, work velocity of 180 mm/s and feed of 0.09 mm/rev, VBmax were decreased 30.3% and 54.3%, respectively, in case of ultrasonic-assisted tuning and ultrasonic elliptical vibration–assisted turning. It was also observed that increasing the amplitude of ultrasonic vibrations reduces VBmax; at work velocity of 180 mm/s and feed of 0.09 mm/rev, the reduction of VBmax in ultrasonic elliptical vibration–assisted turning with amplitudes of 5 and 13 μm is, respectively, 39.3% and 54.3%, compared with that of conventional machining. The results also show that the application of ultrasonic vibrations weakens the cutting tool diffusion wear mechanism. This attenuation is much higher for ultrasonic elliptical vibration–assisted turning in comparison to ultrasonic-assisted tuning. Besides, the amount of attenuation in cutting tool diffusion wear mechanism decreases with increasing vibration amplitude.

Tool Wear in Milling Hardened Die Steel

1998 ◽  
Vol 120 (4) ◽  
pp. 669-673 ◽  
Author(s):  
S. Nelson ◽  
J. K. Schueller ◽  
J. Tlusty
Keyword(s):  
Tool Wear ◽  
Tool Life ◽  
Flank Wear ◽  
Chip Thickness ◽  
Hardened Steel ◽  
Depth Of Cut ◽  
Limiting Factor ◽  
End Mill ◽  
Carbide Inserts ◽  
Cutting Speeds

Tool wear is an important limiting factor in machining hardened steel. Plane milling of H13 hot work tool steel (42–46 HRC) was conducted on a three-axis machine to obtain flank wear data with the objective of finding operating parameters providing extended tool life. Microgram carbide and PCBN tipped carbide round inserts in an off-center ball nose end mill with a single cutting edge were considered. Tool life was longer for the micrograin carbide inserts when cutting speeds were near 150 m/min. The PCBN grades performed best at the highest speed tested. A limited radial and axial depth of cut with a larger maximum chip thickness provided the best tool life over the parameters tested.

CARLSON ALLOY C600 and C600 ESR

Alloy Digest ◽  
1994 ◽  
Vol 43 (11) ◽  
Keyword(s):  
Mechanical Properties ◽  
Solid Solution ◽  
Fracture Toughness ◽  
Cold Working ◽  
Elevated Temperatures ◽  
High Strength ◽  
Heat Treating ◽  
Solid Solution Alloy ◽  
Resistance To Oxidation ◽  
Good Workability

Abstract CARLSON ALLOYS C600 AND C600 ESR have excellent mechanical properties from sub-zero to elevated temperatures with excellent resistance to oxidation at high temperatures. It is a solid-solution alloy that can be hardened only by cold working. High strength at temperature is combined with good workability. This datasheet provides information on composition, physical properties, elasticity, and tensile properties as well as fracture toughness. It also includes information on corrosion resistance as well as forming, heat treating, and machining. Filing Code: Ni-470. Producer or source: G.O. Carlson Inc.

UDIMET 520

Alloy Digest ◽  
1962 ◽  
Vol 11 (9) ◽  
Keyword(s):  
Corrosion Resistance ◽  
Physical Properties ◽  
Surface Treatment ◽  
Tensile Properties ◽  
Elevated Temperatures ◽  
Base Alloy ◽  
High Strength ◽  
Heat Treating ◽  
Nickel Base Alloy ◽  
Nickel Base

Abstract UDIMET 520 is a nickel-base alloy recommended for applications where high strength at elevated temperatures is required. It is suitable for service at temperatures up to 1800 F. This datasheet provides information on composition, physical properties, and tensile properties as well as creep. It also includes information on corrosion resistance as well as forming, heat treating, machining, joining, and surface treatment. Filing Code: Ni-74. Producer or source: Special Metals Inc..

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