Evaluation of Machining-Induced Chatter and Part Quality in TiAl Alloys Turning Processes by Means of Harmonics Analysis

Abstract:

Titanium alloys have been reported as potential materials for aeronautical and automotive applications due to their interesting mechanical properties, combined with their low density. The manufacturing processes developed for these alloys require finishing machining operations to improve the surface quality of the parts and to meet the desired geometrical tolerances. Nevertheless, titanium aluminides exhibit extremely low machinability in comparison to traditional titanium alloys. The combination of the low thermal diffusivity of these materials and the high chemical affinity and friction coefficient with the cutting tools accelerate tool wear phenomena and lead to a deterioration of the part surface quality. Moreover, the mechanical properties of titanium aluminides contribute to increase the cutting forces which generates tool repulsion resulting in undesirable vibration or chatter phenomena. In this paper, the machining suitability of the turning process of Ti48Al2Cr2Nb titanium aluminide has been evaluated based on the analysis of chatter phenomena and the inspection of the surface roughness and roundness tolerance of the machined part. Experimental turning tests have been carried out by varying the main parameters of the process, cutting speed, feed rate and tool geometry, with the objective of determining the best cutting combination. For this purpose, a harmonic analysis methodology of the roundness profile based on the application of the discrete Fourier transform (DFT) has been employed. This technique has made it possible to isolate the vibration-induced machining effects from the lower frequency defects generated by part bending and to relate them to the surface quality and geometrical accuracy of the machined part.

• Periodical: Key Engineering Materials (Volume 959)
• Pages: 149-158
• DOI: https://doi.org/10.4028/p-EfUcv8
• Online since: October 2023
• Authors: Enrique García-Martínez, Valentín Miguel*, María Carmen Manjabacas, Juana Coello, Maria Crina Radu
• Keywords: Chatter Phenomena, Harmonics Analysis, Roundness Tolerance, Titanium Aluminides Machining

References

[1] R. K. Gupta, B. Pant, and P. P. Sinha, "Theory and Practice of γ + α2 Ti Aluminide: A Review," Trans. Indian Inst. Met., vol. 67, no. 2, p.143–165, Apr. 2014.

DOI: 10.1007/s12666-013-0334-y

[2] F. Appel, R. Wagner, and V. Kumar, "Intermetallics: Titanium Aluminides," in Reference Module in Materials Science and Materials Engineering, Elsevier, 2017.

DOI: 10.1016/b978-0-12-803581-8.02542-x

[3] J. C. Williams and R. R. Boyer, "Opportunities and Issues in the Application of Titanium Alloys for Aerospace Components," Metals (Basel)., vol. 10, no. 6, p.705, May 2020.

DOI: 10.3390/met10060705

[4] H. Clemens and H. Kestler, "Processing and Applications of Intermetallic γ-TiAl-Based Alloys," Adv. Eng. Mater., vol. 2, no. 9, p.551–570, Sep. 2000.

DOI: 10.1002/1527-2648(200009)2:9<551::aid-adem551>3.0.co;2-u

[5] J. . Kuang, R. . Harding, and J. Campbell, "Microstructures and properties of investment castings of γ-titanium aluminide," Mater. Sci. Eng. A, vol. 329–331, p.31–37, Jun. 2002.

DOI: 10.1016/S0921-5093(01)01539-8

[6] L. E. Murr et al., "Characterization of titanium aluminide alloy components fabricated by additive manufacturing using electron beam melting," Acta Mater., vol. 58, no. 5, p.1887–1894, Mar. 2010.

DOI: 10.1016/j.actamat.2009.11.032

[7] S. Biamino et al., "Electron beam melting of Ti–48Al–2Cr–2Nb alloy: Microstructure and mechanical properties investigation," Intermetallics, vol. 19, no. 6, p.776–781, Jun. 2011.

DOI: 10.1016/j.intermet.2010.11.017

[8] M. A. K. Chowdhury, A. S. Ullah, and R. Teti, "Optimizing 3D Printed Metallic Object's Postprocessing: A Case of Gamma-TiAl Alloys," Materials (Basel)., vol. 14, no. 5, p.1246, Mar. 2021.

DOI: 10.3390/ma14051246

[9] S. Castellanos and J. Lino Alves, "A review of milling of gamma titanium aluminides," U.Porto J. Eng., vol. 3, no. 2, p.1–9, 2017.

DOI: 10.24840/2183-6493_003.002_0001

[10] E. García-Martínez, A. Martínez-Martínez, M. C. Manjabacas, and V. Miguel, "Proposal of a combined experimental-simulation methodology for the evaluation of machining temperature in turning processes," Meas. J. Int. Meas. Confed.

DOI: 10.1016/j.measurement.2021.110632

[11] S. Castellanos, A. Cavaleiro, A. de Jesus, R. Neto, and J. L. Alves, "Machinability of titanium aluminides: A review," Proc. Inst. Mech. Eng. Part L J. Mater. Des. Appl., p.146442071880938, Nov. 2018.

DOI: 10.1177/1464420718809386

[12] E. Aust and H.-R. Niemann, "Machining of γ-TiAl," Adv. Eng. Mater., vol. 1, no. 1, p.53–57, Sep. 1999, doi: 10.1002/(SICI)1527-2648(199909)1:1<53::AID-ADEM53>3.0.CO;2-3.

DOI: 10.1002/(sici)1527-2648(199909)1:1<53::aid-adem53>3.0.co;2-3

[13] E. García-Martínez, V. Miguel, A. Martínez-Martínez, M. C. Manjabacas, and J. Coello, "Sustainable Lubrication Methods for the Machining of Titanium Alloys: An Overview," Materials (Basel)., vol. 12, no. 23, p.3852, Nov. 2019.

DOI: 10.3390/ma12233852

[14] A. Beranoagirre, D. Olvera, and L. N. López de Lacalle, "Milling of gamma titanium–aluminum alloys," Int. J. Adv. Manuf. Technol., vol. 62, no. 1–4, p.83–88, Sep. 2012.

DOI: 10.1007/s00170-011-3812-6

[15] E. García-Martínez, V. Miguel, A. Martínez, J. A. Naranjo, and J. Coello, "Tribological characterization of tribosystem Ti48Al2Cr2Nb-coated/uncoated carbide tools at different temperatures," Wear, vol. 484–485, p.203992, Nov. 2021.

DOI: 10.1016/j.wear.2021.203992

[16] P. C. Priarone, F. Klocke, M. G. Faga, D. Lung, and L. Settineri, "Tool life and surface integrity when turning titanium aluminides with PCD tools under conventional wet cutting and cryogenic cooling," Int. J. Adv. Manuf. Technol., vol. 85, no. 1–4, p.807–816, Jul. 2016.

DOI: 10.1007/s00170-015-7958-5

[17] P. C. Priarone, M. Robiglio, L. Settineri, and V. Tebaldo, "Effectiveness of Minimizing Cutting Fluid Use when Turning Difficult-to-cut Alloys," Procedia CIRP, vol. 29, p.341–346, 2015.

DOI: 10.1016/j.procir.2015.02.006

[18] F. Klocke, D. Lung, M. Arft, P. C. Priarone, and L. Settineri, "On high-speed turning of a third-generation gamma titanium aluminide," Int. J. Adv. Manuf. Technol., vol. 65, no. 1–4, p.155–163, Mar. 2013.

DOI: 10.1007/s00170-012-4157-5

[19] E. García-Martínez, V. Miguel, A. Martínez-Martínez, J. Coello, J. A. Naranjo, and M. C. Manjabacas, "Optimization of the Dry Turning Process of Ti48Al2Cr2Nb Aluminide Based on the Cutting Tool Configuration," Materials (Basel)., vol. 15, no. 4, p.1472, Feb. 2022.

DOI: 10.3390/ma15041472

[20] W. Zhao, J. Tan, Z. Xue, and S. Fu, "SEST: A new error separation technique for ultra-high precision roundness measurement," Meas. Sci. Technol., vol. 16, no. 3, p.833–841, 2005.

DOI: 10.1088/0957-0233/16/3/027

[21] A. Görög and I. Görögová, "Application of Fourier Series for Evaluation of Roundness Profiles in Metrology," Adv. Sci. Technol. Res. J., vol. 13, no. 4, p.30–38, 2019.

DOI: 10.12913/22998624/113620

[22] Taylor Hobson Ltd., "Exploring Roundness," 2011.

[23] L. A. S. Obse, "ISO 12181-2. Geometrical product specifications (GPS)- roundess- part 2:" 2012.