Processing and Damping Properties of Sputtered NiTi Thin Films for Tools in Machining Processes

Article

Abstract

Nowadays, many manufacturing processes require the machining of complex forms with a high aspect ratio or cavities. Tools with a long overhang length are a common method to meet these requirements. Typical examples for this are boring bars for bore-turning and the milling with very long cutters. These tools tend to vibrate strongly due to their slender shape. The stress-induced transformation of austenite to martensite and the distinctive hysteresis loop allow the NiTi shape memory alloys (SMA) to absorb vibration energy. This article describes the innovative approach to dampen process vibrations by coating the tool shafts of cutting tools with long overhang with NiTi thin films. It explores how these thin films can be applied on polished tungsten carbide shafts and how their modal parameters are modified by these coatings. In a further step, this knowledge is used to calculate stability charts of corresponding machining processes. The study reported in this article identified the stabilizing effects of coatings with a thickness of 2-4 μm on milling processes. The minimum stability limit was increased by up to 200%.

Keywords

damping machining NiTi shape memory alloys simulation thin film 

References

  1. 1.
    D. Enk, T. Surmann, A. Zabel, Analysis of Milling Tool Vibrations Along Changing Engagement Conditions, Proceedings of the 2nd CIRP International Conference on High Performance Cutting, Y. Altintas, Ed., June 12–13, 2006, Vancouver, CanadaGoogle Scholar
  2. 2.
    S. Dong, J. Xiong, A. Li, and P. Lin, A Passive Damping Device with TiNi Shape Memory Alloy Rings and Its Properties, Mater. Sci. Eng. A, 2006, 416, p 92–97CrossRefGoogle Scholar
  3. 3.
    D. Hodgson, Damping Applications of Shape-Memory Alloys. Materials Science Forum, Vol 394–395, Trans Tech Publications, Zurich, 2002, p 69–74Google Scholar
  4. 4.
    Y. Xiaojun, L. Haiyan, and N. Jingxu, SMA Pseudo-Rubber Metal and Its Application in Vibration Control, J. Beijing Univ. Aeronaut Astronaut, 2003, 29(1), p 72–75Google Scholar
  5. 5.
    E. Rivin and X. Like, Damping of NiTi Shape Memory Alloys and Its Application for Cutting Tools, Mater. Noise Vib. Control ASME NCA, 1994, 18, p 35–41Google Scholar
  6. 6.
    A. Shevchenko, Manufacture of New Material with Higher Damping Ability for Superhard Cutting Tools, Eur. Congr. Exhib. Powder Metall. EPMA, 2001, 1, p 423–427Google Scholar
  7. 7.
    J. Frenzel, Z. Zhang, K. Neuking, and G. Eggeler, High Quality Vacuum Induction Melting of Small Quantities of NiTi Shape Memory Alloys in Graphite Crucibles, J. Alloys Compd., 2004, 385, p 214–223CrossRefGoogle Scholar
  8. 8.
    R. de Lima Miranda, C. Zamponi, and E. Quandt, Rotational UV Lithography Device for Cylindrical Substrate Exposure, Rev. Sci. Instrum., 2009, 80, p 015103CrossRefGoogle Scholar
  9. 9.
    T. Yagi, R. Oguro, R. Tamura, S. Takeuchi, Hydrogen-Doped Bulk Metallic Glasses As High Damping Material, Supercooled Liquid, Bulk Glassy and Nanocrystalline States of Alloys, Materials Research Society Symposium Proceedings, Vol 644, Mater. Res. Soc., Warrendale, PA, 2001, p L11.10.1–L11.10.6Google Scholar
  10. 10.
    J. McCormick, R. DesRoches, D. Fugazza, and F. Auricchio, Seismic Vibration Control Using Superelastic Shape Memory Alloys, Trans. ASME J. Eng. Mater. Technol., 2006, 128(3), p 294–301CrossRefGoogle Scholar

Copyright information

© ASM International 2011

Authors and Affiliations

  1. 1.Institute of Machining TechnologyTechnische Universität DortmundDortmundGermany
  2. 2.Functional Materials, Institute for Materials ScienceUniversity of KielKielGermany

Personalised recommendations