Sustainable High Speed Dry Cutting of Magnesium Alloys

Abstract:

Magnesium (Mg) components can significantly reduce energy use due to their low densities compared to the majority alloys. Mg alloys are often machined to fit individual cases. However, process mechanics by high-speed dry cutting of Mg alloys are poorly understood. This study focuses on machining ability of biomedical magnesium-calcium (Mg-Ca) alloys. First, it presents a modeling approach of mechanical behavior of Mg-Ca0.8 (wt %) alloy under cutting regimes using the internal state variable (ISV) plasticity model. Then, the ISV plasticity model is implemented to simulate high speed dry cutting of Mg-Ca0.8 alloy by finite element method. Last, machining performance in the context of sustainability is discussed. Excellent surface finish can be achieved in the range of high cutting speeds. Continuous chip formation predicted by the finite element simulation is verified by high speed dry cutting of Mg-Ca0.8 using polycrystalline diamond (PCD) inserts. Chip ignition as the most hazardous aspect in machining Mg alloys does not occur for in high-speed dry cutting with sharp PCD tools. The predicted temperature distribution well explains the reason for the absence of chip ignition in high speed dry cutting of Mg-Ca0.8 alloy. A mechanism of built-up layer (BUL) formation is proposed.

• Periodical: Materials Science Forum (Volume 723)
• Pages: 3-13
• DOI: https://doi.org/10.4028/www.scientific.net/MSF.723.3
• Online since: June 2012
• Authors: Yue Bin Guo, Zhan Qiang Liu
• Keywords: Dry Cutting, High Speed Machining, Magnesium Alloy, Sustainability

References

[1] G. Byrne, D. Dornfeld and B. Denkena: Ann. CIRP 52 (2003), pp.483-507

DOI: 10.1016/s0007-8506(07)60200-5

[2] T. Hassel, F.W. Bach and C. Krause, in: Proceedings of 7th International Conference on Mg Alloys & Their Applications, pp.789-795 (2007).

[3] B.D. Danilenko: Russ. Eng. Res. 29(3) (2009), pp.316-318

[4] D.L. Hallum: Am. Mach. 139(5) (1995), pp.48-51

[5] H.K. Tönshoff, J. Winkler: Surf. Coat. Technol. 94-95 (1997), pp.610-616

[6] H.K. Tönshoff, T.Friemuth, J. Winkler, C. Podolsky: Mg Alloys & Their Appl. pp.406-411 (2000).

[7] F.Z. Fang, L.C. Lee, X.D. Liu: J. Mater. Process. Technol. Vol. 167 (2005), pp.119-123

[8] T. Friemuth, J. Winkler: Adv. Eng. Mater. 1(3-4) (1999), pp.183-186

[9] W. Pedersen, M. Ramulu: J. Mater. Process. Technol. Vol. 172 (2006), pp.417-423

[10] M. Videm, R.S. Hansen, N. Tomac, K. Tonnesen: SAE Trans. 103 (1994), pp.213-220

[11] N. Tomac, K. Tonnessen, Ann. CIRP 40(1) (1991), pp.79-82

[12] J. Schmidt, J. Winkler, Aluminium 74(6) (1998), pp.412-417

[13] C. Sanz, E. Fuentes, F. Obermair, L. Muntada, in: Proceedings of 7th International Conference on Mg Alloys & Their Applications, pp.916-921 (2007)

[14] R. Schwerin, S. Joksch, in: Proceedings of 7th International Conference on Mg Alloys & Their Applications, 922 – 925 (2007)

[15] Y.B. Guo, M. Salahshoor, CIRP Ann. – Manuf. Technol. Vol. 59 (2010), pp.151-154

[16] F.W. Bach, B. Denkena, K. Weinert, P. Alpers, M. Bosse, N. Hammer, in: Proceedings of 7th International Conference on Mg Alloys & Their Applications, pp.1076-1084 (2007)

[17] Y.B. Guo, V. Brooks, in: Proceedings of ASM Materials & Processes for Medical Devices Conference and Exposition, Minneapolis, MN (2009)

[18] D.J. Bammann, M.L. Chicsa, G.C. Johnson, in: App. Mech. P. 359 – 376 (1996)

[19] Y.B. Guo, C.R. Liu: J. Manuf. Sci. Eng. Vol. 124 (2002), pp.189-199