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Investigation on the high-feed milling of M28

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Abstract

The outstanding combination of strength and fracture toughness as well as the high strength-to-weight ratio make the metastable β titanium alloy an ideal material for aviation applications. The machining of metastable ß titanium alloys remains a challenge due to their poor machinability. In this study, the high-feed milling of a novel metastable β titanium alloy M28 is investigated for the first time to evaluate the performance of a potential high efficiency machining approach for such hard-to-machine material as well as the corresponding surface quality. The cutting force, the effect of chip thickness, and the wear mechanism of the carbide tool coated with TiAlN-Al2O3 are investigated. The influence of feed rate on machined surface microstructures and microhardness of M28 are also studied. The ploughing effect of the inadequate feed-per-tooth in the high-feed milling is revealed in the cutting force experiment. The tool wear is dominated by the notch wear, and the cutting-edge degeneration induced by the carbide matrix fracture accelerates it. The mechanical stress-induced crack, which differs from the thermal crack presented in previous researches, leads to the uneven delamination of the TiAlN-Al2O3 coating. The feed-per-tooth several times than the conventional milling (from 0.6 and 0.8 mm/z) causes no damage to the microstructures while slight grain deformation (as thin as 2.54 μm) can be found as the feed-per-tooth reaches 1.0 mm/z. The microhardness of the machined surface shows a pronounced work hardening tendency of M28, while the tool wear leads to significant grain fragmentation and distortion at the surface and aggravates the work hardening. Since no white layer is found in the cutting of M28, high-feed milling shows the advantage of preventing heat-induced surface damage. It proves that high-feed milling is a promising approach for the high efficiency machining of the metastable titanium alloy.

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Funding

This work was supported by the National Natural Science Foundation of China (No. 52075251).

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Authors and Affiliations

  1. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, China

    Yifan Jiang, Liang Li & Yinfei Yang

  2. AVIC Xi’an Aircraft Industry (Group) Company LTD, Xi’an, 710089, China

    Xu Yang, Hui Tian & Liangdong Ma

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  1. Yifan Jiang
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  2. Xu Yang
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  3. Hui Tian
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  4. Liangdong Ma
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Contributions

All authors contributed to the study conception and design. Material preparation was performed by Yifan Jiang, Xu Yang, and Liangdong Ma. Data collection and analysis were performed by Yifan Jiang, Hui Tian, and Yinfei Yang. The first draft of the manuscript was written by Yifan Jiang with the instruction of Liang Li. All authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

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Correspondence to Liang Li.

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Jiang, Y., Yang, X., Tian, H. et al. Investigation on the high-feed milling of M28. Int J Adv Manuf Technol 129, 127–141 (2023). https://doi.org/10.1007/s00170-023-12005-9

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