Skip to main content

Advertisement

SpringerLink
Log in

VFCVD diamond-coated cutting tools for micro-machining titanium alloy Ti6Al4V

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Diamond-coated cutting tools are known to machine complex materials with many benefits associated with the generation of lower temperatures between contact surfaces. However, the complexity associated with machining exotic materials at the micro-scale eludes many researchers who study phenomena pertinent to the development of new processes for novel micro-structured materials. The study investigated the use of a Lagrangian-Eulerian-formulated finite element program to analyze chip formation and thermal effects when micro-machining Ti6Al4V titanium alloy used for medical device applications. For the simulated machining conditions described in this paper, chip formation occurred when F C/F T >1 and burr formation occurred when F C/F T <1. In addition to the force conditions, when the ratio of feed per tooth to tool edge radius is approximately unity (f tooth/t r ∼1), the micro-machining process forms chips. When the ratio is decreased to equal 0.5 (f tooth/t r = 0.5), chip formation and burr formation exists simultaneously. However, when the ratio approaches an approximate value of 0.3 (f tooth/t r ∼0.3), burr formation is dominant. The study also provides an insight into the thermal effects of micro-machining that shows how vertical filament chemical vapor deposition (VFCVD)-coated tools maintain the integrity of the surfaces of the material as a function of simulated machining parameters. In conclusion, the computational analysis is compared with practical micro-machining results reported in the literature.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. J. P. Davim and M. J. Jackson (eds) (2009) Nano and micromachining. ISTE/Wiley Press, London, UK, 212 pp

  2. D. Tolfree and M. J. Jackson (eds) (2008), Commercializing micro and nanotechnology products. CRC Press-Taylor and Francis Publishers, 269 pp

  3. M. J. Jackson and W. Ahmed (eds) (2014), Emerging nanotechnologies for manufacturing, 2nd edn. William Andrew (Elsevier), Oxford, UK, 551 pp

  4. M. J. Jackson (2013) Micromachining with nanostructured cutting tools. Springer Briefs in Applied Sciences and Technology: Manufacturing and Surface Engineering, pp. 1–55

  5. Ahmed W, Sein H, Jackson M, Rego C, Phoenix D, Elhissi A, Crean SJ, Chemical Vapour Deposition of Diamond for Dental Tools and Burs (2014) Springer briefs in materials: manufacturing and surface engineering series. Springer-Verlag Publishers, Heidelberg, p 140

    Google Scholar 

  6. Ullah M, Ahmed E, Hassan IU, Jackson MJ, Ahmed W (2011) Controlling properties of micro crystalline diamond films using oxygen in a hot filament chemical vapor deposition system. Journal of Manufacturing Technology Research 3(3/4):153–165

    Google Scholar 

  7. Jones AN, Ahmed W, Hassan IU, Rego CA, Sein H, Amar M, Jackson MJ (2003) Impact of inert gases on the structure, properties, and growth of nanocrystalline diamond. Journal of Physics: Condensed Matter—Special Issue on Characterization and Modelling of Group IV Semiconductors 15:2969–2975

    Google Scholar 

  8. Sein H, Ahmed W, Rego CA, Jones AN, Amar M, Jackson MJ, Polini R (2003) C.V.D. Diamond coating on tungsten carbide dental cutting tools. Journal of Physics: Condensed Matter – Special Issue on Characterization and Modelling of Group IV Semiconductors 15:2961–2967

    Google Scholar 

  9. M. J. Jackson, M. D. H. Gill, H. Sein, and W. Ahmed (2003) Manufacture of diamond coated cutting tools for micro machining applications. In: Proceedings of the Institution of Mechanical Engineers (London): part L—Journal of Materials 217, 77–83

  10. Sein H, Ahmed W, Jackson MJ, Woodwards R, Polini R (2004) Performance and characterization of CVD diamond coated, sintered diamond, and WC-co cutting tools for dental and micromachining applications. Thin Solid Films 447-448:455–461

    Article  Google Scholar 

  11. Kim C-J, Mayor JR, Ni J (2004) A static model of chip formation in microscale milling. Transactions of the ASME-Journal of Manufacturing Science and Engineering 126:710–718

    Article  Google Scholar 

  12. Gurin, F.V. 1967 Metal cutting using diamond tools with ground cutting edges. Maschinostryenie, Moscow

  13. Kragelsky IV, Dobychin MN, Kombalov VS (1982) Friction and wear—calculations and methods. Pergamon Press Inc, New York

    Google Scholar 

  14. L’Vov NP (1968) Determining the minimum possible chip thickness. Machines and Tooling 40:45–46

    Google Scholar 

  15. Basuray PK, Misra BK, Lal GK (1977) Transition from ploughing to rubbing. Wear 43:341–349

    Article  Google Scholar 

  16. Vogler MP, Devor RE, Kapoor SG (2004) On the modeling and analysis of machining performance in micro-endmilling. Part I: surface generation. ASME J Manuf Sci Eng 126:685–694

    Article  Google Scholar 

  17. Son SM, Lim HS, Ahn JH (2005) Effects of the friction coefficient on the minimum cutting thickness in micro cutting. International Journal of Machine Tools & Manufacture 45:529–535

    Article  Google Scholar 

  18. Shimada S et al (1993) Feasibility study on ultimate accuracy in Microcutting using molecular dynamics simulation. CIRP Ann 42:91–94

    Article  Google Scholar 

  19. Yuan ZJ, Zhou M, Dong S (1996) Effect of diamond tool sharpness on minimum cutting thickness and cutting surface integrity in ultraprecision machining. J Mater Process Technol 62:327–330

    Article  Google Scholar 

  20. Sun J, Guo YB (2009) Material flow stress and failure in multiscale machining titanium alloy Ti-6Al-4V. Int J Adv Manuf Technol 41:651–659

    Article  Google Scholar 

  21. www.matweb.com. 1996–2016. Available from: http://www.matweb.com/. Accessed November 2016

  22. Blazynski, T.Z., ed. (1987) Materials at high strain rates. Elsevier Applied Science Publishers

  23. Wu XY, Ramesh KT, Wright TW (2003) The effect of thermal softening and heat conduction on the dynamic growth of voids. Int J Solids Struct 40:4461–4478

    Article  MATH  Google Scholar 

  24. Seo S, Min O, Yang H (2005) Constitutive equation for Ti-6Al-4V at high temperatures measured using the SHPB technique. International Journal of Impact Engineering 31:735–754

    Article  Google Scholar 

  25. Khan AS, Suh YS, Kazmi R (2004) Quasi-static and dynamic loading responses and constitutive modeling of titanium alloys. Int J Plast 20:2233–2248

    Article  MATH  Google Scholar 

  26. Henry, S.D., K.S. Dragolich, and N.D. DiMatteo (1995) Fatigue data book: light structural alloys. ASM International

  27. Kang IS, Kim SK, Seo YW (2008) Cutting force model considering tool edge geometry for micro end milling process. J Mech Sci Technol 22:293–299

    Article  Google Scholar 

  28. Barry J, Byrne G, Lennon D (2001) Observations on chip formation and acoustic emission in machining Ti-6Al-4V alloy. Int J Mach Tools Manuf 41:1055–1070

    Article  Google Scholar 

  29. Cotterell M, Byrne G (2008) Characterization of chip formation during orthogonal cutting of titanium alloy Ti6Al4V. CIRP J Manuf Sci Technol 1(2):81–85

    Article  Google Scholar 

  30. Robinson, G. M. (2007) Wear of nanostructured coated cutting tools during mixed scale machining. Ph.D. thesis, Purdue University, West Lafayette, United States of America

  31. Kim JD, Kim DS (1995) Theoretical analysis of micro cutting characteristics in ultra precision machining. J Mater Process Technol 49:387–398

    Article  Google Scholar 

  32. Özel T, Zeren E (2007) Finite element analysis of the influence of edge roundness on the stress and temperature fields induced by high speed machining. Int J Adv Manuf Technol 35(3–4):255–267

    Article  Google Scholar 

  33. Li R, Shih AJ (2006) Finite element modeling of 3D turning of titanium. Int J Adv Manuf Technol 29:253–261

    Article  Google Scholar 

  34. Umbrello D (2008) Finite element simulation of conventional and high speed machining of Ti6Al4V alloy. J Mater Process Technol 196:79–87

    Article  Google Scholar 

  35. Obikawa T, Usui E (1996) Computational machining of Ti alloy finite element modeling. Transactions of the ASME J Manuf Sci Eng 118:208–215

    Article  Google Scholar 

  36. Shi J, Liu RC (2004) The influence of material models on finite element simulation machining. Transactions of the ASME J Manuf Sci Eng 126:849–857

    Article  Google Scholar 

  37. Usui E, Shirakashi T, Kitagawa T (1978) Cutting temperature and crater wear of carbide tools. Transactions of the ASME Journal of Engineering for Industry 100(2):236–243

    Article  Google Scholar 

  38. Kitagawa T, Kubo A, Maekawa K (1997) Temperature and wear of cutting tools in high speed machining of Inconel 718 and Ti-6Al-6V-2Sn. Wear 202(2):515–525

    Article  Google Scholar 

  39. Kim KW, Lee WY, Sin HC (1999) A finite element analysis of machining with the tool edge considered. J Mater Process Technol 86:45–55

    Article  Google Scholar 

  40. Cao ZY, He N, Li L (2008) A finite element analysis of micro/meso scale machining considering the cutting edge radius. Appl Mech Mater 10-12:631–636

    Article  Google Scholar 

  41. Venkatesh V, Swain N, Srinivas G, Kumar P, Barshilla H (2016) Review on the machining characteristics and research prospects of conventional microscale machining operations. Mater Manuf Process:1–28.39. doi:10.1080/10426914.2016.1151045

  42. T. Novakov (2010) Computational analysis of micromachining Ti6Al4V titanium alloy. Ph.D. thesis, Purdue University, West Lafayette, United States of America

  43. Jackson MJ, Novakov T, da Silva MB, Machado AR (2016) Predicting chip and non-chip formation when micromachining Ti6Al4V titanium alloy. Int J Adv Manuf Technol. doi:10.1007/s001170-016-9754-2

    Google Scholar 

  44. Aslantas K, Hopa HE, Percin M, Ucun I, Çicek A (2016) Cutting performance of nano-crystalline diamond (NCD) coating in micro-milling of Ti6Al4V alloy. Precis Eng 45:55–66

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Center for Advanced Manufacturing, Purdue University, West Lafayette, IN, USA

    Mark J. Jackson, Tamara Novakov, Michael Whitfield, Grant Robinson & Rodney Handy

  2. Kansas State University, Manhattan, KS, USA

    Mark J. Jackson

  3. Department of Chemistry, Manchester Metropolitan University, Manchester, UK

    Htet Sein

  4. School of Mathematics and Physics, University of Lincoln, Lincoln, UK

    Waqar Ahmed

Authors
  1. Mark J. Jackson
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Tamara Novakov
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Michael Whitfield
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Grant Robinson
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Rodney Handy
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Htet Sein
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Waqar Ahmed
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Mark J. Jackson.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Jackson, M.J., Novakov, T., Whitfield, M. et al. VFCVD diamond-coated cutting tools for micro-machining titanium alloy Ti6Al4V. Int J Adv Manuf Technol 92, 2881–2918 (2017). https://doi.org/10.1007/s00170-017-0334-x

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-017-0334-x

Keywords

Search

Navigation