Abstract
This work systematically studied morphology of nano- and microstructures in primary and secondary shear zones of machining chips produced with two different machining methods: conventional and ultrasonically assisted turning. Electron backscatter diffraction and transmission electron microscopy showed that chips had similar microstructures for both machining techniques. The nanostructure in secondary shear zones was less homogeneous than that in primary shear zones. In addition, a heavily deformed layer was formed in a subsurface of Ti-15V-3Cr-3Al-3Sn work-pieces, replicating the microstructure of secondary shear zones of the machining chips, and elongated nanocrystalline grains in this layer were aligned with a tangential direction of turning.
Similar content being viewed by others
References
R.R. Boyer and R.D. Briggs, The Use of β Titanium Alloys in the Aerospace Industry, J. Mater. Eng. Perform., 2005, 14, p 681–685
J. Sun and Y.B. Guo, A Comprehensive Experimental Study on Surface Integrity by End Milling Ti-6Al-4V, J. Mater. Process. Technol., 2009, 209, p 4036–4042
C. Brecher, C.J. Rosen, and M. Emonts, Laser-Assisted Milling of Advanced Materials, Phys. Proc., 2010, 5, p 259–272
R. Muhammad, A. Naseer, A. Roy, and V.V. Silberschmidt, Numerical Modelling of Vibration-Assisted Turning of Ti-15333, Proc. CIRP, 2012, 1, p 347–352
A. Maurotto, R. Muhammad, A. Roy, V.I. Babitsky, and V.V. Silberschmidt, Comparing Machinability of Ti-15-3-3-3 and Ni-625 Alloys in Uat, Proc. CIRP, 2012, 1, p 330–335
R. Muhammad, N. Ahmed, A. Roy, and V.V. Silberschmidt, Turning of Advanced Alloys with Vibrating Cutting Tool, Solid State Phenom., 2012, 188, p 277–284
R. Muhammad, M. Demiral, A. Roy, and V.V. Silberschmidt, Modelling the Dynamic Behaviour of Hard-to-Cut Alloys Under Conditions of Vibro-Impact Cutting, J. Phys. Conf. Ser., 2013, 451(1), p 012030
R. Muhammad, A. Roy, and V. V. Silberschmidt, Finite Element Modelling of Conventional and Hybrid Oblique Turning Processes of Titanium Alloy, 14th CIRP Conference on Modelling of Machining Operations, 2013, p 510–515.
R. Muhammad, A. Maurotto, M. Demiral, A. Roy, and V.V. Silberschmidt, Thermally Enhanced Ultrasonically Assisted Machining of Ti Alloy, CIRP J. Manuf. Sci. Technol., 2014, 7, p 159–167
A. Maurotto, R. Muhammad, A. Roy, and V.V. Silberschmidt, Enhanced Ultrasonically Assisted Turning of a β-Titanium Alloy, Ultrasonics, 2013, 53, p 1242–1250
R. Muhammad, A. Maurotto, A. Roy, and V.V. Silberschmidt, Hot Ultrasonically Assisted Turning of β-Ti Alloy, Proc. CIRP, 2012, 1, p 336–341
V.I. Babitsky, A.V. Mitrofanov, and V.V. Silberschmidt, Ultrasonically Assisted Turning of Aviation Materials: Simulations and Experimental Study, Ultrasonics, 2004, 42(1–9), p 81–86
N. Ahmed, A.V. Mitrofanov, V.I. Babitsky, and V.V. Silberschmidt, Analysis of Forces in Ultrasonically Assisted Turning, J. Sound Vib., 2007, 308(3–5), p 845–854
P.-J. Arrazola, A. Garay, L.-M. Iriarte, M. Armendia, and S. Marya, Machinability of Titanium Alloys (Ti6Al4V) and Ti555.3, J. Mater. Process. Technol., 2009, 209, p 2223–2230
A.I.S. Antonialli, A.A.M. de Filho, V.L. Sordi, and M. Ferrante, The Machinability of Ultrafine-Grained Grade 2 Ti Processed by Equal Channel Angular Pressing, J. Mater. Res. Technol., 2012, 1, p 148–153
C. Ohkubo, I. Watanabe, J.P. Ford, H. Nakajima, and T. Tosoi, The Machinability of Cast Titanium and Ti-6Al-4V Alloy, Int. J. Mach. Tool Manuf., 2001, 41, p 1055–1070
J. Barry, G. Byrne, and D. Lennon, Observation of Chip Formation and Acoustic Emission in Machining Ti-6Al-4V Alloy, Int. J. Mach. Tool Manuf., 2001, 41, p 1055–1070
G. Sutter and G. List, Very High Speed Cutting of Ti-6Al-4V Titanium Alloy—Change in Morphology and Mechanism of Chip Formation, Int. J. Mach. Tool Manuf., 2013, 66, p 37–43
J. Hua and R. Shivpuri, Prediction of Chip Morphology and Segmentation During the Machining of Titanium Alloys, J. Mater. Process. Technol., 2004, 150, p 124–133
M.J. Bermingham, S. Palanisamy, D. Kent, and M.S. Dargusch, A Comparison of Cryogenic and High Pressure Emulsion Cooling Technologies on Tool Life and Chip Morphology in Ti-6Al-4V Cutting, J. Mater. Process. Technol., 2012, 212, p 752–765
S. Cedergren, G. Petti, and G. Sjöberg, On the Influence of Work Material Microstructure on Chip Formation, Cutting Forces and Acoustic Emission When Machining Ti-6Al-4V, Proc. CIRP, 2013, 12, p 55–60
S. Sun, M. Brandt, and M.S. Dargusch, Characteristics of Cutting Forces and Chip Formation in Machining of Titanium Alloys, Int. J. Mach. Tool Manuf., 2009, 49, p 561–568
M. Sima and T. Özel, Modified Material Constitutive Models for Serrated Chip Formation Simulations and Experimental Validation in Machining of Titanium Alloy Ti-6Al-4V, Int. J. Mach. Tool Manuf., 2010, 50, p 943–960
M. Calamaz, D. Coupard, and F. Girot, A New Material Model for 2D Numerical Simulation of Serrated Chip Formation When Machining Titanium Alloy Ti-6Al-4V, Int. J. Mach. Tool Manuf., 2008, 48, p 275–288
A. Molinari, C. Musquar, and G. Sutter, Adiabatic Shear Banding in High Speed Machining of Ti-6Al-4V: Experiments and Modelling, Int. J. Plast, 2002, 18, p 443–459
R. Shivpuri, J. Hua, P. Mittal, A.K. Srivastava, and G.D. Lahoti, Microstructure-Mechanics Interactions in Modelling Chip Segmentation During Titanium Machining, CIRP Ann. Manuf. Technol., 2002, 51, p 71–74
Y. Karpat, Temperature Dependent Flow Softening of Titanium Alloy Ti6Al4V: An Investigation Using Finite Element Simulation of Machining, J. Mater. Process. Technol., 2011, 211, p 737–749
M.P. Groover, Fundamentals of Modern Manufacturing Materials, Processes, and Systems, 3rd ed., Wiley, New York, 2007
M.C. Shaw, Metal Cutting Principle, 2nd ed., Oxford University Press, Oxford, 2005
P. Rokicki, K. Nowag, Z. Spotz, L. Fusova, K. Saksl, R. Ghisleni, and C. Siemers, Microstructural Characteristic of Ti-15V-3Al-3Sn-3Cr Chips, Int. J. Earth Sci., 2010, 55, p 452–456
P. Rokicki, K. Nowag, Z. Spotz, L. Fusova, K. Saksl, R. Ghisleni, C. Siemers, Chip Formation Process of Ti-15V-3Al-3Sn-3Cr Alloy, 19th International Conference on Metallurgy and Materials, vol. METAL, 2010, p 844–849.
X. Zhao, W. Fu, X. Yang, and T.G. Langdon, Microstructure and Properties of Pure Titanium Processed by Equal-Channel Angular Pressing at Room Temperature, Scr. Mater., 2008, 59, p 542–545
U.F. Kocks and H. Mecking, Physics and Phenomenology of Strain Hardening: The FCC Case, Prog. Mater. Sci., 2003, 48(3), p 171–273
Y. Estrin, L.S. Tóth, A. Molinari, and Y. Bréchet, A Dislocation-Based Model for All Hardening Stages in Large Strain Deformation, Acta Mater., 1998, 46(15), p 5509–5522
S. Swaminathan, M. Ravi Shankar, S. Lee, J. Hwang, A.H. King, R.F. Kezar, B.C. Rao, T.L. Brown, S. Chandrasekar, W.D. Compton, and K.P. Trumble, Large Strain Deformation and Ultrafine Grained Materials by Machining, Mat. Sci. Eng. A, 2005, 410–411, p 358–363
W.J. Deng, W. Xia, C. Li, and Y. Tang, Ultrafine Grained Material Produced by Machining, Mater. Manuf. Process., 2010, 25, p 355–359
S.Y. Hong, Y. Ding, and W. Jeong, Friction and Cutting Forces in Cryogenic Machining of Ti-6Al-4V, Int. J. Mach. Tool Manuf., 2001, 41(15), p 2271–2285
V.K. Astashev and V.I. Babitsky, Ultrasonic Cutting as a Nonlinear (Vibro-Impact) Process, Ultrasonics, 1998, 36, p 89–96
B. Langenecker, Effects of Ultrasound on Deformation Characteristics of Metals, IEEE Trans. Sonic Ultrason., 1966, 13, p 12–13
R. Muhammad, M.S. Hussain, A. Maurotto, C. Siemers, A. Roy, and V.V. Silberschmidt, Analysis of a Free Machining α + β Titanium Alloy Using Conventional and Ultrasonically Assisted Turning, J. Mater. Process. Technol., 2014, 214(4), p 906–915
S. To, Y.H. Zhu, and W.B. Lee, Effects of Cutting Depth on the Surface Microstructure of a Zn-Al Alloy During Ultra-Precision Machining, Appl. Surf. Sci., 2008, 254(6), p 1559–1564
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Shi, Q., Tse, Y.Y., Muhammad, R. et al. Effect of Machining on Shear-Zone Microstructure in Ti-15V-3Cr-3Al-3Sn: Conventional and Ultrasonically Assisted Turning. J. of Materi Eng and Perform 25, 3766–3773 (2016). https://doi.org/10.1007/s11665-016-2209-y
Received:
Revised:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11665-016-2209-y