Skip to main content
SpringerLink
Log in

Observation of a unique wear morphology of cBN inserts during machining of titanium metal matrix composites (Ti-MMCs); leading to new insights into their machinability

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

Abstract

Titanium-based metal matrix composite (T-MMC) is a relatively new material with increasing demand in different industries particularly in aerospace. Yet, there is a significant lack of knowledge regarding its machinability. Tool wear mechanisms of cBN inserts during turning of TiMMCs including adhesion, abrasion, chemical interactions, and their effects on the wear surface morphology were investigated. A unique wear morphology was observed on both rake and flank surfaces, consisting of different distinct zones. The mechanisms leading to this morphology were discussed for the first time, which has led to new understandings and insights into the machinability of Ti-MMCs and more generally into machinability of titanium-based materials. High-magnification imaging revealed a discontinuity within the adhered material to the tool that appeared as a black zone surrounding the contact area. The brittle fracture in this black zone suggested embrittlement of the adhered material in this region. Further investigation confirmed that a very small amount of magnesium in the workpiece material, which is an impurity left over from the production of the titanium alloy, has a key role in this regard. Thus, it could have a profound effect on the machinability of this class of material. Furthermore, magnesium oxidation was found as the main root cause of fire hazard which is known as one of the main issues associated with machining of titanium-based alloys.

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

Reference

  1. Davim JP, Pramanik A, Arsecularatne JA, and Zhang LC (2008) “Machining of Particulate-Reinforced Metal Matrix Composites,” in Machining, ed: Springer London, pp. 127–166

  2. Bhushan RK, Kumar S, Das S (2010) Effect of machining parameters on surface roughness and tool wear for 7075 Al alloy SiC composite. Int J Adv Manuf Technol 50:459–469

    Article  Google Scholar 

  3. Heath PJ (2001) Developments in applications of PCD tooling. J Mater Process Technol 116:31–38

    Article  Google Scholar 

  4. Lin H, Liao Y, Wei C (2008) Wear behavior in turning high hardness alloy steel by CBN tool. Wear 264:679–684

    Article  Google Scholar 

  5. Aouici H, Yallese MA, Chaoui K, Mabrouki T, Rigal J-F (2012) Analysis of surface roughness and cutting force components in hard turning with CBN tool: prediction model and cutting conditions optimization. Measurement 45:344–353

    Article  Google Scholar 

  6. Hung NP, Venkatesh VC, Loh NL (1998) Cutting tools for metal matrix composites. Key Eng Mater 138-140:289–325

    Article  Google Scholar 

  7. Klimczyk P, Figiel P, Petrusha I, Olszyna A (2011) Cubic boron nitride based composites for cutting applications. Journal of Achievements in Materials and Manufacturing Engineering 44:198–204

    Google Scholar 

  8. Monteiro SN, Skury ALD, de Azevedo MG, Bobrovnitchii GS (2013) Cubic boron nitride competing with diamond as a superhard engineering material–an overview. Journal of Materials Research and Technology 2:68–74

    Article  Google Scholar 

  9. Chiou S-Y, Ou S-F, Jang Y-G, Ou K-L (2013) Research on CBN/TiC composites Part1: effects of the cBN content and sintering process on the hardness and transverse rupture strength. Ceram Int 39:7205–7210

    Article  Google Scholar 

  10. Bindal MM, Singhal SK, Singh BP, Nayar RK, Chopra R, Dhar A (1991) Synthesis of cubic boron nitride using magnesium as the catalyst. J Cryst Growth 112:386–401

    Article  Google Scholar 

  11. Astakhov VP (2013) In: Davim JP (ed) “tribology of cutting tools,” in Tribology in Manufacturing Technology. Springer, Berlin Heidelberg, pp 1–66

    Google Scholar 

  12. Ciftci I, Turker M, Seker U (2004) CBN cutting tool wear during machining of particulate reinforced MMCs. Wear 257:1041–1046

    Article  Google Scholar 

  13. Ding X, Liew W, Liu X (2005) Evaluation of machining performance of MMC with PCBN and PCD tools. Wear 259:1225–1234

    Article  Google Scholar 

  14. Yanming Q, Zehua Z (2000) Tool wear and its mechanism for cutting SiC particle-reinforced aluminium matrix composites. J Mater Process Technol 100:194–199

    Article  Google Scholar 

  15. Dabade UA, Dapkekar D, Joshi SS (2009) Modeling of chip-tool interface friction to predict cutting forces in machining of Al/SiCp composites. Int J Mach Tools Manuf 49:690–700

    Article  Google Scholar 

  16. Angseryd J, Andrén H-O (2011) An in-depth investigation of the cutting speed impact on the degraded microstructure of worn PCBN cutting tools. Wear 271:2610–2618

    Article  Google Scholar 

  17. Poulachon G, Moisan A, Jawahir IS (2001) Tool-wear mechanisms in hard turning with polycrystalline cubic boron nitride tools. Wear 250:576–586

    Article  Google Scholar 

  18. Farhat ZN (2003) “Wear mechanism of CBN cutting tool during high-speed machining of mold steel,” Materials Science & Engineering A (Structural Materials: Properties, Microstructure and Processing), vol. A361:100–10

  19. Ezugwu EO, Da Silva RB, Bonney J, Machado AR (2005) “Evaluation of the performance of CBN tools when turning Ti-6Al-4V alloy with high pressure coolant supplies,” International Journal of Machine Tools &amp. Manufacture 45:1009–1014

    Google Scholar 

  20. Lin HM, Liao YS, Wei CC (2008) Wear behavior in turning high hardness alloy steel by CBN tool. Wear 264:679–684

    Article  Google Scholar 

  21. Barry J, Byrne G (2001) Cutting tool wear in the machining of hardened steels. Part II: cubic boron nitride cutting tool wear. Wear 247:152–160

    Article  Google Scholar 

  22. Nasr MNA, Ghandehariun A, Kishawy HA (2016) A physics-based model for metal matrix composites deformation during machining: a modified constitutive equation. J Eng Mater Technol 139:011003–011003

    Article  Google Scholar 

  23. Abkowitz S, Fisher H (2011) Breakthrough claimed for titanium PM. Metal Powder Report 66:16–21

    Article  Google Scholar 

  24. Hihara LH, Adler RP, and Latanision RM (2013) Environmental degradation of advanced and traditional engineering materials: CRC Press

  25. Clark RK and Unnam J (1983) “Residual mechanical properties of Ti-6Al-4V after simulated Space Shuttle reentry,” NASA Technical Memorandum

  26. Godfrey TMT, Wisbey A, Goodwin PS, Bagnall K, Ward-Close CM (2000) Microstructure and tensile properties of mechanically alloyed Ti–6A1–4V with boron additions. Mater Sci Eng A 282:240–250

    Article  Google Scholar 

  27. Mashinini PM (2010) Process window for friction stir welding of 3 mm titanium (Ti-6Al-4V). Nelson Mandela Metropolitan University, Research dissertation

    Google Scholar 

  28. Kumar S, Balasubramanian V (2010) Effect of reinforcement size and volume fraction on the abrasive wear behaviour of AA7075 Al/SiCp P/M composites—a statistical analysis. Tribol Int 43:414–422

    Article  Google Scholar 

  29. Murray J (1986) The Mg− Ti (magnesium-titanium) system. Bull Alloy Phase Diagr 7:245–248

    Article  Google Scholar 

  30. Bhaumik SK, Divakar C, Singh AK (1995) Machining Ti-6Al-4V alloy with a WBN-CBN composite tool. Mater Des 16:221–226

    Article  Google Scholar 

  31. R. Bejjani, M. Balazinski, B. Shi, H. Attia, and H. Kishawy, “Machinability and chip formation of Titanium Metal Matrix Composites (Ti-MMCs),” Int. J. of Advanced Manufacturing Systems, IJAMS, vol. 13, 2011.

  32. Wenfeng D, Jiuhua X, Zhenzhen C, Honghua S, Yucan F (2010) Effects of heating temperature on interfacial microstructure and compressive strength of brazed CBIN-AlN composite abrasive grits. Journal of Wuhan University of Technology - Materials Science Edition 25:952–956

    Article  Google Scholar 

  33. Ding WF, Xu JH, Fu YC, Xiao B, Su HH, Xu HJ (2006) Interfacial reaction between cubic boron nitride and Ti during active brazing. J Mater Eng Perform 15:365–369 2006/06/01

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Mechanical Engineering, Polytechnique Montreal, Édouard-Montpetit, Montréal, QC, H3T 1J4, Canada

    Maryam Aramesh & Marek Balazinski

  2. Aerospace structures, materials and manufacturing laboratory of the National Research Council Canada (NRC), Avenue Decelles, Campus de l’Université de Montréal, 1280 Main Street West, Montreal, QC, H3T 2B2, Canada

    Helmi M. Attia

  3. Mechanical Engineering Department, University of Ontario Institute of Technology, 2000 Simcoe St N, Oshawa, ON, L1H 7K4, Canada

    Hossam A. Kishawy

Authors
  1. Maryam Aramesh
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Helmi M. Attia
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Hossam A. Kishawy
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Marek Balazinski
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Maryam Aramesh.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Aramesh, M., Attia, H.M., Kishawy, H.A. et al. Observation of a unique wear morphology of cBN inserts during machining of titanium metal matrix composites (Ti-MMCs); leading to new insights into their machinability. Int J Adv Manuf Technol 92, 519–530 (2017). https://doi.org/10.1007/s00170-017-0146-z

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-017-0146-z

Keywords

Search

Navigation