Analysis of Machinability of Ti- and Ni-Based Alloys

Abstract:

Article Preview

Efficient machining of advanced Ti- and Ni-based alloys, which are typically difficult-to-machine, is a challenge that needs to be addressed by the industry. During a typical machining operation of such alloys, high cutting forces imposed by a tool on the work-piece material lead to severe deformations in the process zone, along with high stresses, strains and temperatures in the material, eventually affecting the quality of finished work-piece. Conventional machining (CT) of Ti- and Ni-based alloys is typically characterized by low depths of cuts and relatively low feed rates, thus adversely affecting the material removal rates (MRR) in the machining process. In the present work, a novel machining technique, known as Ultrasonically Assisted Turning (UAT) is shown to dramatically improve machining of these intractable alloys. The developed machining process is capable of high MRR with an improved surface quality of the turned work-piece. Average cutting forces are significantly lower in UAT when compared to those in traditional turning techniques at the same machining parameters, demonstrating the capability of vibration-assisted machining as a viable machining method for the future.

Info:

Periodical:

Solid State Phenomena (Volume 188)

Edited by:

Mircea Nicoară, Aurel Răduţă and Carmen Opriş

Pages:

330-338

Citation:

A. Maurotto et al., "Analysis of Machinability of Ti- and Ni-Based Alloys", Solid State Phenomena, Vol. 188, pp. 330-338, 2012

Online since:

May 2012

Export:

Price:

$38.00

[1] Ma, J., Wang, Q., 1998. Aging characterization and application of Ti-15-3 alloy. Material Science and Engineering A, 243(1), pp.150-154.

[2] Mathew, M.D., Parameswaran, P., Bhanu Sankara Rao, K., 2008. Microstructural changes in alloy 625 during high temperature creep. Materials Characterization, 59(5), pp.508-513.

DOI: https://doi.org/10.1016/j.matchar.2007.03.007

[3] Ezugwu, E.O., 2005. Key improvements in the machining of difficult-to-cut aerospace superalloys. International Journal of Machine Tools and Manufacture, 45(12)-(13), pp.1353-1367.

DOI: https://doi.org/10.1016/j.ijmachtools.2005.02.003

[4] Ribeiro, M.V., Moreira, M.R.V. and Ferreira, J.R., 2003. Optimization of titanium alloy (6Al–4V) machining. Journal of Materials Processing Technology, 143-144, pp.458-463.

DOI: https://doi.org/10.1016/s0924-0136(03)00457-6

[5] Ezugwu, E.O., Bonney, J. and Yamane, Y., 2003. An overview of the machinability of aeroengine alloys. Journal of Materials Processing Technology, 134(2), pp.233-253.

DOI: https://doi.org/10.1016/s0924-0136(02)01042-7

[6] Sokovic, M., Mijanovic, K., 2001. Ecological aspects of the cutting fluids and its influence on quantifiable parameters of the cutting processes. Journal of Material Processing Technology, 109(1)-(2), pp.181-189.

DOI: https://doi.org/10.1016/s0924-0136(00)00794-9

[7] DMG, 2010. DMG D4839/0210ND1; In: Ultrasonic Series; ULTRASONICS hard machining and milling on one machine.

[8] Babitsky, V.I., Mitrofanov, A., Silberschmidt, V.V., 2003. Ultrasonically assisted turning of aviation materials. Journal of Materials Processing Technology, 132, pp.157-167.

DOI: https://doi.org/10.1016/s0924-0136(02)00844-0

[9] Maurotto, A., Roy, A., Babitsky, V.I., Silberschmidt, V.V., Recent developments in ultrasonically assisted machining of advanced alloys. In: CIRP, 4th CIRP International Conference on High Performance Cutting. Gifu, Japan, 24-26 October (2010).

[10] Jin, M and Murakawa, M., 2001. Development of a practical ultrasonic vibration cutting tool system. Journal of Materials Processing Technology, 113, pp.342-347.

DOI: https://doi.org/10.1016/s0924-0136(01)00649-5

[11] Brehl, D.E. and Dow, T.A., 2008. Review of vibration-assisted machining. Precision Engineering , 32, pp.153-172.

DOI: https://doi.org/10.1016/j.precisioneng.2007.08.003

[12] Informationon http: /www. harrison. co. uk.

[13] Information on http: /www. kistler. com.

[14] Information on http: /www. polytec. de/uk.

[15] Information on http: /ecat. secotools. com.

[16] Astashev, V.K. and Babitsky, V.I., 1998. Ultrasonic cutting as a non-lineal (vibro-impact) process, Ultrasonics, 36, pp.89-96.

DOI: https://doi.org/10.1016/s0041-624x(97)00101-7

[17] Muhammad, R., Maurotto, A., Roy, A., Silberschmidt, V.V., Characterization of thermomechanical loads in vibro-impact machining of advanced alloys. In: BSSM, International Conference on Advances in Experimental Mechanics: Integrating Simulation and Experimentation for Validation. Edinburgh, Scotland, 7-9 September (2011).

[18] Ahmed, N., Mitrofanov, A., Babitsky, V.I., Silberschmidt, V.V., 2006. Analysis of material response to ultrasonic vibration loading in turning Inconel 718, Material Science and Engineering A, 424, pp.318-325.

DOI: https://doi.org/10.1016/j.msea.2006.03.025

[19] Mitrofanov, A.V., Ahmed, N., Babitsky, V.I., Silberschmidt, V.V., 2005. Effects of lubrication and cutting parameters on ultrasonically assisted turning of Inconel 718, Journal of Materials Processing Technology, 162-163, pp.649-654.

DOI: https://doi.org/10.1016/j.jmatprotec.2005.02.170