Advertisement

Material removal mechanism of PTMCs in high-speed grinding when considering consecutive action of two abrasive grains

  • Huan Zhou
  • Wenfeng DingEmail author
  • Chaojie Liu
ORIGINAL ARTICLE
  • 59 Downloads

Abstract

An effective finite element (FE) simulation model characterizing the material removal behavior of TiCp/Ti-6Al-4V titanium matrix composites in high-speed grinding process was developed when considering consecutive action of two abrasive grains. The resultant stress and grinding force have been analyzed to study the crack propagation behavior. The effect of the undeformed chip thickness on the ground surface defects was discussed. It was found that in the material removal process of PTMCs, the brittle removal of TiCp and the plastic removal of Ti-6Al-4V matrix would happen simultaneously until the reinforcing particle completely failed in the grinding process. The maximum Mises stress and single-grain grinding forces fluctuate weakly and smoothly once the crack is produced in the reinforcing TiCp. As for the reinforcing TiCp without crack inside, the crushing depth increases with the increase of the undeformed chip thickness in grinding. However, as for the TiCp with residual crack inside, due to the stress concentration in the tip of the crack, the TiCp is always cracked in chunks when the undeformed chip thickness changes from 0.3 to 0.9 μm in grinding. Finally, the FE simulation results are validated true through the high-speed grinding experiment of PTMCs.

Keywords

PTMCs FE simulation model Material removal mechanism Crack 

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

Notes

Funding information

The authors gratefully acknowledge the financial support for this work from the National Natural Science Foundation of China (No. 51775275), the Fundamental Research Fund for the Central University (No. NE2014103), and the Foundation of Graduate Innovation Center in NUAA (No. KFJJ20170527).

References

  1. 1.
    Rastegari HA, Asgari S, Abbasi SM (2011) Producing Ti-6Al-4V/TiC composite with good ductility by vacuum induction melting furnace and hot rolling process. Mater Des 32(10):5010–5014CrossRefGoogle Scholar
  2. 2.
    Huang LJ, Geng L, Peng HX (2010) In situ (TiBw +TiCp)/Ti6Al4V composites with a network reinforcement distribution. Mater Sci Eng A 527:6723–6727CrossRefGoogle Scholar
  3. 3.
    Zhang YZ, Sun JC, Vilar R (2011) Characterization of (TiB+TiC)/TC4 in situ titanium matrix composites prepared by laser direct deposition. J Mater Process Technol 211:597–601CrossRefGoogle Scholar
  4. 4.
    Choi BJ, Kim ILY, Lee YZ, Kim YJ (2014) Microstructure and friction/wear behavior of (TiB+TiC) particulate-reinforced titanium matrix composites. Wear 318:68–77CrossRefGoogle Scholar
  5. 5.
    Jackson MJ, Davis CJ, Hitchiner MP, Mills B (2001) High-speed grinding with CBN grinding wheels-applications and future technology. J Mater Process Technol 110:78–88CrossRefGoogle Scholar
  6. 6.
    Zhang DK, Li CH, Zhang YB, Jia DZ, Zhang XW (2015) Experimental research on the energy ratio coefficient and specific grinding energy in nanoparticle jet MQL grinding. Int J Adv Manuf Technol 78:1275–1288CrossRefGoogle Scholar
  7. 7.
    Zhang XP, Li CH, Zhang YB, Zhang XW (2016) Performances of Al2O3/SiC hybrid nanofluids in minimum-quantity lubrication grinding. Int J Adv Manuf Technol 86:3427–3441CrossRefGoogle Scholar
  8. 8.
    Zhang DK, Li CH, Jia DZ (2015) Specific grinding energy and surface roughness of nanoparticle jet minimum quantity lubrication in grinding. Chin J Aeronaut 28(2):570–581CrossRefGoogle Scholar
  9. 9.
    Mao C, Zhang J, Huang Y, Zou HF, Huang XM, Zhou ZX (2013) Investigation on the effect of nanofluid parameters on MQL grinding. Mater Manuf Process 28:436–442CrossRefGoogle Scholar
  10. 10.
    Mao C, Zou HF, Zhou X, Huang Y, Gan HY, Zhou ZX (2014) Analysis of suspension stability for nanofluid applied in minimum quantity lubricant grinding. Int J Adv Manuf Technol 71:2073–2081CrossRefGoogle Scholar
  11. 11.
    Qi H, Wen DH, Yuan QL, Zhang L, Chen ZZ (2017) Numerical investigation on particle impact erosion in ultrasonic-assisted abrasive slurry jet micro-machining of glasses. Powder Technol 314:627–634CrossRefGoogle Scholar
  12. 12.
    Qi H, Wen DH, Lu CD, Li G (2016) Numerical and experimental study on ultrasonic vibration-assisted micro-channelling of glasses using an abrasive slurry jet. Int J Mech Sci 110:94–107CrossRefGoogle Scholar
  13. 13.
    Thiagarajan C, Sivaramakrishnan R, Somasundaram S (2011) Experimental evaluation of grinding forces and surface finish in cylindrical grinding of Al/SiC metal matrix composites. Proc Inst Mech Eng B J Eng Manuf 225(9):1606–1614CrossRefGoogle Scholar
  14. 14.
    Huang ST, Yu XL, Wang FS, Xu LF (2015) A study on chip shape and chip-forming mechanism in grinding of high volume fraction SiC particle reinforced Al-matrix composites. Int J Adv Manuf Technol 80:1927–1932CrossRefGoogle Scholar
  15. 15.
    Blau PJ, Jolly BC (2009) Relationships between abrasive wear, hardness, and grinding characteristics of titanium-based metal-matrix composites. J Mater Eng Perform 18(4):424–432CrossRefGoogle Scholar
  16. 16.
    Zhu Y, Kishawy HA (2005) Influence of alumina particles on the mechanics of machining metal matrix composites. Int J Mach Tools Manuf 45:389–398CrossRefGoogle Scholar
  17. 17.
    Pramanik A, Zhang LC, Arsecularatne JA (2007) An FEM investigation into the behavior of metal matrix composites: tool–particle interaction during orthogonal cutting. Int J Mach Tools Manuf 47(10):1497–1506CrossRefGoogle Scholar
  18. 18.
    Ghandehariun A, Kishawy H, Balazinski M (2016) On machining modeling of metal matrix composites: a novel comprehensive constitutive equation. Int J Mech Sci 107:235–241CrossRefGoogle Scholar
  19. 19.
    Umer U, Ashfaq M, Qudeiri JA (2015) Modeling machining of particle-reinforced aluminum-based metal matrix composites using cohesive zone elements. Int J Adv Manuf Technol 78:1171–1179CrossRefGoogle Scholar
  20. 20.
    Dandekar CR, Shin YC (2009) Multi-step 3-D finite element modeling of subsurface damage in machining particulate reinforced metal matrix composites. Compos A: Appl Sci Manuf 40:1231–1239CrossRefGoogle Scholar
  21. 21.
    Azarhoushang B, Tawakoli T (2011) Development of a novel ultrasonic unit for grinding of ceramic matrix composites. Int J Adv Manuf Technol 57:945–955CrossRefGoogle Scholar
  22. 22.
    Liu CJ, Ding WF, Yu TY, Yang CY (2018) Materials removal mechanism in high-speed grinding of particulate reinforced titanium matrix composites. Precis Eng 51:68–77CrossRefGoogle Scholar
  23. 23.
    Wang T, Xie LJ, Wang XB (2015) Simulation study on defect formation mechanism of the machined surface in milling of high volume fraction SiCp/Al composite. Int J Adv Manuf Technol 79:1185–1194CrossRefGoogle Scholar
  24. 24.
    Wang BB, Xie LJ, Chen XL, Wang XB (2016) The milling simulation and experimental research on high volume fraction of SiCp/Al. Int J Adv Manuf Technol 82:809–816CrossRefGoogle Scholar
  25. 25.
    Kotkunde N, Krishnamurthy HN, Puranik P, Gupta AK, Singh SK (2014) Microstructure study and constitutive modeling of Ti–6Al–4V alloy at elevated temperatures. Mater Des 54:96–103CrossRefGoogle Scholar
  26. 26.
    Akbari M, Buhl S, Leinenbach C, Wegener K (2016) A new value for Johnson Cook damage limit criterion in machining with large negative rake angle as basis for understanding of grinding. J Mater Process Technol 234:58–71CrossRefGoogle Scholar
  27. 27.
    Guerrini G, Bruzzone AAG, Crenna F (2017) Single grain grinding: an experimental and FEM assessment. Procedia CIRP 62:287–292CrossRefGoogle Scholar
  28. 28.
    Fu DK, Ding WF, Yang SB, Miao Q, Fu YC (2017) Formation mechanism and geometry characteristics of exit-direction burrs generated in surface grinding of Ti-6Al-4V titanium alloy. Int J Adv Manuf Technol 89:2299–2313CrossRefGoogle Scholar
  29. 29.
    Ghandehariun A, Kishawy HA, Umer U, Hussein MH (2016) Analysis of tool-particle interactions during cutting process of metal matrix composites. Int J Adv Manuf Technol 82:143–152CrossRefGoogle Scholar
  30. 30.
    Gao CY, Zhang LC (2013) Effect of cutting conditions on the serrated chip formation in high-speed cutting. Mach Sci Technol 17(1):26–40CrossRefGoogle Scholar
  31. 31.
    Chen G, Ren C, Yang XY, Jin XM, Guo T (2011) Finite element simulation of high-speed machining of titanium alloy (Ti–6Al–4V) based on ductile failure model. Int J Adv Manuf Technol 56:1027–1038CrossRefGoogle Scholar
  32. 32.
    Masanta M, Shariff SM, Choudhury AR (2011) Evaluation of modulus of elasticity, nano-hardness and fracture toughness of TiB2-TiC-Al2O3 composite coating developed by SHS and laser cladding. Mater Sci Eng A 528:5327–5335CrossRefGoogle Scholar
  33. 33.
    Ding WF, Zhu YJ, Zhang LC, Xu JH, Fu YC, Liu WD, Yang CY (2015) Stress characteristics and fracture wear of brazed CBN grains in monolayer grinding wheels. Wear 332-333:800–809CrossRefGoogle Scholar
  34. 34.
    Zhu D, Yan S, Li B (2014) Single-grit modeling and simulation of crack initiation and propagation in SiC grinding using maximum undeformed chip thickness. Comput Mater Sci 92:13–21CrossRefGoogle Scholar
  35. 35.
    Chen JY, Xu XP (2014) Tribological characteristics in high-speed grinding of alumina with brazed diamond wheels. Int J Adv Manuf Technol 71:1579–1585CrossRefGoogle Scholar
  36. 36.
    Li Z, Ding WF, Liu CJ, Su HH (2016) Prediction of grinding temperature of PTMCs based on the varied coefficients of friction in conventional-speed and high-speed surface grinding. Int J Adv Manuf Technol 90:2335–2344CrossRefGoogle Scholar
  37. 37.
    Xu XP, Li Y, Malkin S (2001) Forces and energy in circular sawing and grinding of granite. J Manuf Sci Eng 123(1):13–22CrossRefGoogle Scholar

Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2018

Authors and Affiliations

  1. 1.College of Mechanical and Electrical EngineeringNanjing University of Aeronautics and AstronauticsNanjingPeople’s Republic of China

Personalised recommendations