Advertisement

Journal of Failure Analysis and Prevention

, Volume 14, Issue 1, pp 102–112 | Cite as

Surface Integrity and Fatigue Behavior for High-Speed Milling Ti–10V–2Fe–3Al Titanium Alloy

  • C. -F. Yao
  • L. Tan
  • J. -X. Ren
  • Q. Lin
  • Y. -S. Liang
Technical Article---Peer-Reviewed
First Online:
Received:

Abstract

Influence of cutting parameters on surface integrity when milling Ti–10V–2Fe–3Al is investigated based on high-speed cutting experiments. Surface integrity measurements, fatigue fractography analysis, and fatigue life tests are conducted to reveal the effect of surface integrity on crack initiation and fatigue life. The results show that under given experiment conditions, surface roughness decreases linearly when increasing cutting speed or decreasing feed per tooth. The latter has a greater impact on surface roughness than the former. Compressive stress can be detected on all machined surfaces. With the increase of feed per tooth or cutting speed, respectively, residual stress presents a linear increase. Cutting parameters have no significant impact on micro-hardness. When the surface roughness ranges from 0.5 to 1.0 μm, the effect of surface residual stress on fatigue life is more than that of surface roughness. When the surface residual compressive stress increases, the fatigue life improves significantly. Compared with 60 m/min, when cutting speed is 100 or 140 m/min, the surface roughness decreases, the surface residual compressive stress increases, and the fatigue life improves by 124 and 59%, respectively. Under a tensile load, fatigue crack on machined surface of Ti–10V–2Fe–3Al titanium alloy originates at the cross-edge of the specimen surface. With the increase of surface roughness, the area ratio of fatigue crack propagation zone, and fatigue fracture zone decreases.

Keywords

Ti–10V–2Fe–3Al titanium alloy High-speed milling Surface integrity Fatigue life Fatigue fracture 
This is a preview of subscription content, log in to check access.

Notes

Acknowledgements

The authors wish to thank the support of the National Natural Science Foundation of China (Grant Nos.50975237, 51005184 and 51375393), National Science and Technology Major Project of the Ministry of Science and Technology of China (Grant No. 2013ZX04011031), and the Aeronautical Science Foundation of China (2013ZE53060).

Reference

  1. 1.
    M.J. Wang, X.J. Meng, Z.Q. Liao, S.K. Li, Present state of research on Ti-1023 titanium alloy. Dev. Appl. Mater. 24(5), 66–69 (2009). (in Chinese)Google Scholar
  2. 2.
    Y.K. Gao, Y.F. Yin, X.B. Li, Influence of surface integrity on fatigue property for martensite stainless steel. Heat Treat. Metals 27(8), 30–32 (2002). (in Chinese)Google Scholar
  3. 3.
    D.C. Zhang, X.M. Pei, Effects of machining processes on surface roughness and fatigue life. Chin. J. Mech. Eng. 14(16), 1374–1377 (2003). (in Chinese)Google Scholar
  4. 4.
    J. Sun, Y.B. Guo, A comprehensive experimental study on surface integrity by end milling Ti-6Al-4V. J. Mater. Process. Technol. 209(8), 4036–4042 (2009)CrossRefGoogle Scholar
  5. 5.
    G.A. Ibrahim, C.H. Che Haron, J.A. Ghani, The effect of dry machining on surface integrity of titanium alloy Ti-6Al-4V ELI. J. Appl. Sci. 9(1), 121–127 (2009)CrossRefGoogle Scholar
  6. 6.
    N. Elmagrabi, C.H. Che Hassan, A.G. Jaharah, F.M. Shuaeib, High speed milling of Ti-6Al-4V using coated carbide tools. Eur. J. Sci. Res. 22(2), 153–162 (2008)Google Scholar
  7. 7.
    C.H. Che-Haron, Tool life and surface integrity in turning titanium alloy. J. Mater. Process. Technol. 118(1–3), 231–237 (2001)CrossRefGoogle Scholar
  8. 8.
    C.H. Che-Haron, A. Jawaid, The effect of machining on surface integrity of titanium alloy Ti-6%Al-4%V. J. Mater. Process. Technol. 166(2), 188–192 (2005)CrossRefGoogle Scholar
  9. 9.
    A.L. Mantle, D.K. Aspinwall, Surface integrity of a high-speed milled gamma titanium aluminide. J. Mater. Process. Technol. 18(1–3), 143–150 (2001)CrossRefGoogle Scholar
  10. 10.
    X.K. Shi, Q.F. Yang, W. Cai et al., Study on high speed milling surface integrity of Ti alloy TC4. Aeronaut. Manuf. Technol. 36(1), 30–31 (2001). (in Chinese)Google Scholar
  11. 11.
    S.G. Du, C. Lv, J.X. Ren, Z.C. Yang, Study on surface morphology and microstructure of titanium alloy TC4 under high-speed milling. Acta Aeronaut. Astronaut. Sinica 29(16), 1710–1715 (2008). (in Chinese)Google Scholar
  12. 12.
    Z.C. Yang, D.H. Zhang, C.F. Yao, J.X. Ren, S.G. Du, Effects of high-speed milling parameters on surface integrity of TC4 titanium alloy. J. Northwest. Polytech. Univ. 27(4), 538–543 (2009). (in Chinese)Google Scholar
  13. 13.
    I.S. Jawahir, E. Brinksmeier, R. M’Saoubi et al., Surface integrity in material removal processes: recent advances. CIRP Ann. Manuf. Technol. 60(2), 603–626 (2011)CrossRefGoogle Scholar
  14. 14.
    D. Arola, M. Ramulu, An examination of the effects from surface texture on the strength of fiber reinforced plastics. J. Compos. Mater. 33(2), 102–123 (1999)CrossRefGoogle Scholar
  15. 15.
    D. Arola, C.L. Williams, Estimating the fatigue stress concentration factor of machined Surfaces. Int. J. Fatigue 24(9), 923–930 (2002)CrossRefGoogle Scholar
  16. 16.
    G. Zhang, J. Liu, Y.S. Liu, Z.F. Yue, Effect of roughness on surface stress concentration coefficient and fatigue life. J. Mech. Strength 32(1), 110–115 (2010). (in Chinese)Google Scholar
  17. 17.
    Y.J. Li, F.Z. Xuan, Z.D. Wang, S.T. Tu, Effects of residual stresses on the high cycle fatigue behavior of Ti-6Al-4V. ASME. Press. Vessel. Pip. Conf. 5(2010), 397–401 (2010)Google Scholar
  18. 18.
    D.X. Du, D.X. Liu, Y.F. Sun, J.G. Tang, The effects of machined workpiece surface integrity on the fatigue life of TC21 titanium alloy. Adv. Mater. Res. 503–504, 382–389 (2012)CrossRefGoogle Scholar
  19. 19.
    S.K. Ås, B. Skallerud, B.W. Tveiten, Surface roughness characterization for fatigue life predictions using finite element analysis. Int. J. Fatigue 30(12), 2200–2209 (2008)CrossRefGoogle Scholar
  20. 20.
    D. Novovic, R.C. Dewes, D.K. Aspinwall, W. Voice, P. Bowen, The effect of machined topography and integrity on fatigue life. Int. J. Mach. Tools Manuf. 44(2–3), 125–134 (2004)CrossRefGoogle Scholar
  21. 21.
    M.K. Yang, J.K. Ren, Influence of surface integrity on fatigue life of GH4169. Aviat. Precis. Manuf. Technol. 32(6), 28–31 (1996). (in Chinese)Google Scholar
  22. 22.
    Y.B. Guo, A.W. Warren, The impact of surface integrity by hard turning vs. grinding on fatigue damage mechanisms in rolling contact. Surf. Coat. Technol. 203, 291–299 (2008)CrossRefGoogle Scholar
  23. 23.
    F. Klocke, D. Welling, J. Dieckmanna, Comparison of grinding and Wire EDM concerning fatigue strength and surface integrity of machined Ti6Al4V components. Proc. Eng. 9, 184–189 (2011)CrossRefGoogle Scholar
  24. 24.
    S.K. Jha, K.S. Ravichandran, Effect of mean stress (stress ratio) and aging on fatigue-crack growth in a metastable beta titanium alloy Ti-10V-2Fe-3Al. Metall. Mater. Trans. A 31(3), 703–714 (2000)CrossRefGoogle Scholar
  25. 25.
    C. Li, Y.H. He, L.J. Huang, B. Su, Study on fatigue property and crack growth behavior of Ti-10-2-3 titanium alloy. Fail. Anal. Prev. 3(3), 17–22 (2008). (in Chinese)Google Scholar
  26. 26.
    Q.R. Wang, L.J. Huang, X. Huang, C.K. Liu, D.L. Liu, Effect of droplet on high cycle fatigue property of Ti-10-2-3 titanium alloy. Chin. J. Rare Metals 33(3), 295–298 (2009). (in Chinese)Google Scholar
  27. 27.
    H.O. Fochs, R.I. Stephens, Metal Fatigue in Engineering (Wiley, New York, 1980)Google Scholar

Copyright information

© ASM International 2013

Authors and Affiliations

  • C. -F. Yao
    • 1
  • L. Tan
    • 1
  • J. -X. Ren
    • 1
  • Q. Lin
    • 1
  • Y. -S. Liang
    • 1
  1. 1.The Key Laboratory of Contemporary Design and Integrated Manufacturing Technology, Ministry of EducationNorthwestern Polytechnical UniversityXi’anPeople’s Republic of China

Personalised recommendations

Cite article

Buy options