Hostname: page-component-76fb5796d-22dnz Total loading time: 0 Render date: 2024-04-25T17:21:51.834Z Has data issue: false hasContentIssue false
  • English
  • Français

The influence of cutting parameters on the defect structure of subsurface in orthogonal cutting of titanium alloy

Published online by Cambridge University Press:  17 October 2017

Jinxuan Bai ,
Qingshun Bai ,
Zhen Tong  and
Guoda Chen
Jinxuan Bai*
Affiliation:
School of Mechanical and Electrical Engineering, Harbin Institute of Technology, Harbin 150001, China
Qingshun Bai*
Affiliation:
School of Mechanical and Electrical Engineering, Harbin Institute of Technology, Harbin 150001, China
Zhen Tong
Affiliation:
Centre for Precision Technologies, University of Huddersfield, Huddersfield HD1 3DH, U.K.
Guoda Chen
Affiliation:
Key Laboratory of E & M, Ministry of Education & Zhejiang Province, Zhejiang University of Technology, Hangzhou 310032, People’s Republic of China
*
a) Address all correspondence to these authors. e-mail: jinxuanbai@hit.edu.cn
b) e-mail: qshbai@hit.edu.cn
Get access

Abstract

Subsurface microstructure alteration has been a major concern to implement micromachining of titanium alloy in the high-tech industry. To quantitatively promulgate the underlying mechanisms of this alteration, a discrete dislocation dynamics-based model is proposed and used to simulate the subsurface defects and their evolution under different cutting conditions. The model considers the subsurface dislocation configuration and inner stress distribution during the orthogonal cutting of titanium alloy. The results show that subsurface defect structure consists of plenty of dislocation dipoles, twining dislocation bands, and refined grains after cutting. In the primary shear zone, two different characteristics of subsurface damage layers can be found, the near-surface damage layer and deep-surface damage layer, which have different structural natures and distribution features. Moreover, it is found that high cutting speed and small depth of the cut can suppress the formation and propagation of subsurface defects. A powerful inner stress state would promote the distortion of the lattice and result in a microcrack within the subsurface matrix. The simulation results have been compared with experimental findings on the machined surface and subsurface of similar materials, and strong similarities were revealed and discussed.

Keywords

titanium alloysubsurface defect structureinner stressdislocation dynamics
Type
Articles
Information
Journal of Materials Research , Volume 33 , Issue 6 , 28 March 2018 , pp. 720 - 732
Check for updates
Copyright
Copyright © Materials Research Society 2017 

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

Footnotes

Contributing Editor: Jürgen Eckert

References

REFERENCES

Tan, L., Zhang, D.H., Yao, C.F., Wu, D.X., and Zhang, J.Y.: Evolution and empirical modeling of compressive residual stress profile after milling, polishing and shot peening for TC17 alloy. J. Manuf. Process 26, 155–165 (2017).Google Scholar
Saoubi, R.M., Outeiro, J.C., Chandrasekaran, H., Dillon, O.W., and Jawahir, I.S.: A review of surface integrity in machining and its impact on functional performance and life of machined products. Int. J. Sustainable Manuf. 1, 203–236 (2008).CrossRefGoogle Scholar
Ulutan, D. and Ozel, T.: Machining induced surface integrity in titanium and nickel alloys: A review. Int. J. Mach. Tool Manufact. 51, 250–280 (2011).CrossRefGoogle Scholar
Tan, T.H. and Yan, J.W.: Atomic-scale characterization of subsurface damage and structural changes of single-crystal silicon carbide subjected to electrical discharge machining. Acta Mater. 123, 362–372 (2017).Google Scholar
Che-Haron, C.H.: Tool life and surface integrity in turning titanium alloy. J. Mater. Process. Technol. 118, 231–237 (2001).Google Scholar
Sharman, A.R.C., Hughes, J.J., and Ridgway, K.: Workpiece surface integrity and tool life issues when turning Inconel 718 nickel based superalloy. Mach. Sci. Technol. 8, 399–414 (2004).Google Scholar
Bushlya, V., Zhou, J.M., and Stahl, J.E.: Modeling and experimentation on multistage work-hardening mechanism in machining with nose-radiused tools and its influence on machined subsurface quality and tool wear. Int. J. Adv. Des. Manuf. Technol. 73, 545–555 (2014).Google Scholar
Jawahir, I.S., Brinksmeier, E., Saoubi, R.M., Aspinwall, D.K., Outeiro, J.C., Meyer, D., Umbrello, D., and Jayal, A.D.: Surface integrity in material removal processes: Recent advances. CIRP Ann. 60, 603–626 (2011).Google Scholar
Ginting, A. and Nouari, M.: Surface integrity of dry machined titanium alloys. Int. J. Mach. Tool Manufact. 49, 325–332 (2009).Google Scholar
Thomas, M., Turnerb, S., and Jackson, M.: Microstructural damage during high-speed milling of titanium alloys. Scr. Mater. 62, 250–253 (2010).Google Scholar
Kwong, J., Axinte, D.A., and Withers, P.J.: The sensitivity of Ni-based superalloy to hole making operations: Influence of process parameters on subsurface damage and residual stress. J. Mater. Process. Technol. 209, 3968–3977 (2009).Google Scholar
Jin, D. and Liu, Z.Q.: Damage of the machined surface and subsurface in orthogonal milling of FGH95 superalloy. Int. J. Adv. Des. Manuf. Technol. 68, 1573–1581 (2013).Google Scholar
Lv, D.X., Wang, H.X., Zhang, W.W., and Yin, Z.Q.: Subsurface damage depth and distribution in rotary ultrasonic machining and conventional grinding of glass BK7. Int. J. Adv. Des. Manuf. Technol. 86, 2361–2371 (2016).CrossRefGoogle Scholar
Zhang, S.J., To, S., Cheung, C.F., and Zhu, Y.: Micro-structural changes of Zn–Al alloy influencing micro-topographical surface in micro-cutting. Int. J. Adv. Des. Manuf. Technol. 72, 9–15 (2014).Google Scholar
Bai, J.X., Bai, Q.S., Tong, Z., Hu, C., and He, X.: Evolution of surface grain structure and mechanical properties in orthogonal cutting of titanium alloy. J. Mater. Res. 31, 1–11 (2016).Google Scholar
Guo, Y.B., Li, W., and Jawahir, I.S.: Surface integrity characterization and prediction in machining of hardened and difficult-to-machine alloys: A state-of-the-art research review and analysis. Mach. Sci. Technol. 13, 437–470 (2009).Google Scholar
Gurusamy, M.M. and Rao, B.C.: On the performance of modified Zerilli–Armstrong constitutive model in simulating the metal-cutting process. J. Manuf. Process 28, 253–265 (2017).Google Scholar
Ding, H.T. and Shin, Y.C.: Multi-physics modeling and simulations of surface microstructure alteration in hard turning. J. Mater. Process. Technol. 213, 877–886 (2013).Google Scholar
Hore, S., Das, S.K., Banerjee, S., and Mukherjee, S.: Computational modelling of static recrystallization and two dimensional microstructure evolution during hot strip rolling of advanced high strength steel. J. Mater. Process. Technol. 17, 78–87 (2015).Google Scholar
Wang, Q.L., Bai, Q.S., Chen, J.X., Guo, Y.B., and Xie, W.K.: Stress-induced formation mechanism of stacking fault tetrahedra in nano-cutting of single crystal copper. Appl. Surf. Sci. 355, 1153–1160 (2015).Google Scholar
Li, J., Fang, Q.H., Liu, Y.W., and Zhang, L.C.: A molecular dynamics investigation into the mechanisms of subsurface damage and material removal of monocrystalline copper subjected to nanoscale high speed grinding. Appl. Surf. Sci. 303, 331–343 (2014).Google Scholar
Shishvan, S.S. and Van der Giessen, E.: Mode I crack analysis in single crystals with anisotropic discrete dislocation plasticity: I. Formation and crack growth. Modell. Simul. Mater. Sci. Eng. 21, 065006 (2013).Google Scholar
Shishvan, S.S. and Van der Giessen, E.: Mode I crack analysis in single crystals with anisotropic discrete dislocation plasticity: II. Stationary crack-tip fields. Modell. Simul. Mater. Sci. Eng. 21, 065007 (2013).Google Scholar
Tarleton, E., Balint, D.S., Gong, J., and Wilkinson, A.K.: A discrete dislocation plasticity study of the micro-cantilever size effect. Acta Mater. 88, 271–282 (2015).Google Scholar
Che-Haron, C.H. and Jawaid, A.: The effect of machining on surface integrity of titanium alloy Ti–6Al–4V. J. Mater. Process. Technol. 166, 188–192 (2005).Google Scholar
Crawforth, P., Wynne, B., Turnerb, S., and Jackson, M.: Subsurface deformation during precision turning of a near-alpha titanium alloy. Scr. Mater. 67, 842–845 (2012).Google Scholar
Bermingham, M.J., McDonald, S.D., Dargusch, M.S., and StJohn, D.H.: Grain-refinement mechanisms in titanium alloys. J. Mater. Res. 23, 97–104 (2008).Google Scholar
Wang, Q.Q., Liu, Z.Q., Wang, B., Song, Q.H., and Wan, Y.: Evolutions of grain size and micro-hardness during chip formation and machined surface generation for Ti–6Al–4V in high-speed machining. Int. J. Adv. Des. Manuf. Technol. 82, 1725–1736 (2016).CrossRefGoogle Scholar
Ouyang, C.J., Li, Z.H., Huang, M.S., and Hou, C.T.: Discrete dislocation analyses of circular nanoindentation and its size dependence in polycrystals. Acta Mater. 56, 2706–2717 (2008).CrossRefGoogle Scholar
Ahmed, N. and Hartmaier, A.: A two-dimensional dislocation dynamics model of the plastic deformation of polycrystalline metals. J. Mech. Phys. Solids 58, 2054–2064 (2010).Google Scholar
Benzerga, A.A., Brechet, Y., Needleman, A., and Van der Giessen, E.: Incorporating three-dimensional mechanisms into two-dimension dislocation dynamics. Modell. Simul. Mater. Sci. Eng. 12, 159–196 (2004).Google Scholar
Davoudi, K.M., Nicola, L., and Vlassak, J.J.: Dislocation climb in two-dimensional discrete dislocation dynamics. J. Appl. Phys. 111, 103522 (2012).CrossRefGoogle Scholar
Danas, K. and Deshpande, V.S.: Plane-strain discrete dislocation plasticity with climb-assisted glide motion of dislocations. Modell. Simul. Mater. Sci. Eng. 21, 45008–45033 (2013).Google Scholar
Zhang, Y.C., Mabrouki, T., Nelias, D., and Gong, Y.D.: Chip formation in orthogonal cutting considering interface limiting shear stress and damage evolution based on fracture energy approach. Finite Elem. Anal. Des. 47, 850–863 (2011).Google Scholar
Huang, M.S. and Li, Z.H.: Coupled DDD–FEM modeling on the mechanical behavior of microlayered metallic multilayer film at elevated temperature. J. Mech. Phys. Solids 85, 74–97 (2015).CrossRefGoogle Scholar
Sun, J. and Guo, Y.B.: A comprehensive experimental study on surface integrity by end milling Ti–6Al–4V. J. Mater. Process. Technol. 209, 4036–4042 (2009).Google Scholar
Shin, D.H., Kim, I., Kim, J., Kim, Y.S., and Semiatin, S.L.: Microstructure development during equal-channel angular pressing of titanium. Acta Mater. 51, 83–996 (2003).Google Scholar
Jiang, B., He, T.T., Gu, Y.P., Wang, Q.L., and Cao, G.L.: Method for recognizing wave dynamics damage in high-speed milling cutter. Int. J. Adv. Manuf. Technol., 92, 139–150 (2017).Google Scholar