Machining of titanium alloy (Ti-6Al-4V) - theory to application

This paper correlates laboratory based understanding in machining of titanium alloys with theindustry based outputs and find possible solutions to improve machining efficiency oftitanium alloy Ti-6Al-4V. The machining outputs are explained based on different aspects ofchip formation mechanism and practical issues faced by industries during titaniummachining. This study also analyzed and linked the methods that effectively improve themachinability of titanium alloys. It is found that the deformation mechanism duringmachining of titanium alloys is complex and causes basic challenges, such as saw-toothchips, high temperature, high stress on cutting tool, high tool wear and undercut parts. Thesechallenges are correlated and affected by each other. Saw tooth-chips cause variation incutting forces which results in high cyclic stress on cutting tools. On the other hand, lowthermal conductivity of titanium alloy causes high temperature. These cause a favorableenvironment for high tool wear. Thus, improvements in machining titanium alloy dependmainly on overcoming the complexities associated with the inherent properties of this alloy.Vibration analysis kit, high pressure coolant, cryogenic cooling, thermally enhancedmachining, hybrid machining and, use of high conductive cutting tool and tool holdersimprove the machinability of titanium alloy

On the mechanism of tool crater wear in titanium alloy machining

Today the aerospace industry spends hundreds of millions of dollars on the machining of titanium alloy components. And with increasing aircraft orders, there is pressure to machine at higher production rates and develop more machinable alloys (e.g. TIMETAL® 54M, TMETAL® 407) without compromising titanium’s excellent mechanical properties. Increasing the tool life by a factor of minutes can have a dramatic effect on machining cost. Unlike steels, the same tool grade is used for all titanium alloy types from alpha to beta rich, with the latter being more difficult to machine. Diffusion dominated crater wear is the primary tool wear phenomena which has yet to be fully understood. This thesis demonstrates the application of a low cost diffusion couple technique which gives a strong indication of the complex reaction mechanisms occurring at the tool-chip interface during the machining of titanium alloys. These small scale tests have been validated with large scale dynamic machining trials and strong agreement has been observed. The results have allowed for hypotheses to be made over the reaction mechanisms behind tool crater wear underpinned by key observations in the literature. Such a testing regime can be incorporated into alloy design approaches to inform the industry e.g. TIMET and Rolls-Royce about the ‘machinability’ qualities at a much earlier stage before costly machining trials. Such a method will also aid tool manufacturers to tailor tool carbide grades as well as new coatings to specific alloy chemistries. This is the first time that small scale testing such as this has shown why different alloy chemistries exhibit different tool wear characteristics. The technique is now being developed further by the aerospace manufacturing supply chain including tool manufacturers and titanium alloy producers. It will be used to; (a) develop more machinable alloys at an earlier stage in the alloy design development and (b) match different titanium alloys to more appropriate tool materials and new coatings. As such this thesis should be of interest to a broad readership including mechanical engineers and materials scientists as well as the machining and manufacturing community

Influência da deposição de filmes finos de TiN e ZrN multicamadas na resistência ao desgaste microabrasivo da liga Ti-40Zr obtida por metalurgia do pó

Tese (doutorado)—Universidade de Brasília, Faculdade de Tecnologia, Departamento de Engenharia Mecânica, 2014.Titânio e suas ligas são conhecidos por apresentarem excelentes propriedades mecânicas e inúmeras possibilidades de utilização de acordo com sua composição. Entretanto a baixa resistência ao desgaste restringe o uso de ligas de titânio em atividades que envolvam abrasão. O objetivo deste trabalho foi avaliar a influência da deposição de filmes finos de TiN e ZrN multicamadas na resistência ao desgaste microabrasivo da liga Ti-40Zr obtida por metalurgia do pó. Os filmes foram obtidos por deposição física de vapores por feixe de elétrons, com três diferentes configurações: Ti/TiN, Ti/TiN/ZrN e Ti/TiN/ZrN/TiN. Ensaios de desgaste microabrasivo por esfera livre foram realizados com duas diferentes suspensões abrasivas: uma à base de carbeto de silício, com concentração volumétrica de 0,20 e outra à base de sílica, com concentração volumétrica de 0,23. Foram estudados também 5 diferentes modelos de equações de desgaste com intuito de verificar o que melhor se ajusta com os resultados obtidos experimentalmente, a partir dos coeficientes de determinação e correlação. Foram realizadas caracterizações por meio de ensaio de riscamento, difratometria de raios-X, microscopia eletrônica de varredura, microscopia confocal a laser e microscopia de força atômica. Dentre os abrasivos utilizados, o carbeto de silício apresentou maior coeficiente de desgaste para todas as amostras em função de sua maior dureza e tamanho de partículas. Os coeficientes de desgaste revelaram que todas as amostras revestidas tiveram desempenho superior quando comparadas à amostra sem revestimento, independente do abrasivo utilizado: redução de 69% e 66% para amostras revestidas com TiN, 64% e 64% para amostras revestidas com TiN/ZrN e 59% e 19% para amostras revestidas com TiN/ZrN/TiN, para os abrasivos SiC e SiO2, respectivamente. Dentre os modelos usados para determinação dos coeficientes, os de Archard e Allspopp apresentaram maiores valores nos coeficientes de determinação e correlação, demonstrando melhor ajuste aos dados obtidos experimentalmente. A microscopia de força atômica não revelou correlação entre a rugosidade do filme e sua resistência ao desgaste, evidenciando todavia, uma dependência entre a rugosidade e o tipo de filme. O teste de riscamento analisado pela microscopia confocal a laser demonstrou que a deposição das multicamadas gerou baixa adesão entre as mesmas, tornando-as mais suscetíveis à delaminação com o incremento no número de camadas e, como consequência, redução da resistência ao desgaste. A dissimilaridade composicional entre os filmes TiN e ZrN pode ter gerado tensões residuais durante a deposição, causando delaminação entre os mesmos.Titanium and their alloys are known to have excellent mechanical properties and numerous possibilities of use, according to their composition. However, the lower wear resistance restricts the use of titanium alloys in activities involving abrasion. The aim of this work was evaluate the influence of thin films deposition of TiN and ZrN multilayers in micro-abrasive wear resistance of Ti-40Zr alloy, obtained by powder metallurgy. The thin films were obtained by physical vapor deposition, by electron beam, with three different settings: Ti/TiN, Ti/TiN/ZrN e Ti/TiN/ZrN/TiN. Free ball micro-abrasive wear tests were performed with two different abrasive slurries: a silicon carbide-based, with volumetric concentration of 0,20 and the other silica-based, with volumetric concentration of 0,23. Moreover, 05 different models of wear equations in order to verify which best fits with the results obtained experimentally, from the determination and correlation coefficients. Characterizations were performed by scratching test, X-ray diffraction, scanning electron microscopy, confocal laser microscopy and atomic force microscopy. Among abrasive used, silicon carbide showed higher wear coefficient for all samples due their greater hardness and size of particles. The wear coefficients revealed that all coated samples exhibited superior performance when compared to the uncoated sample, regardless of the abrasive used: reduction of 69% and 66% for samples coated with TiN, 64% and 64% for samples coated with TiN/ZrN and 59% and 19% for samples coated with TiN/ZrN/TiN, to SiO2 and SiC abrasives, respectively. Among the models used to determine the coefficients, Archard and Allspopp presented higher values in the determination and correlation coefficients, and shows a better fit to the data obtained experimentally. Atomic force microscopy revealed no correlation between the roughness of the film and its wear resistance, showing however, a dependency between the roughness and the type of film. The scratching test analyzed by confocal laser microscopy showed that the multilayer deposition produced low adherence between the layers, making them more susceptible to delamination by increasing the number of layers and, consequently, reduced wear resistance. The compositional dissimilarity between the TiN and ZrN films may have generated residual stresses during the deposition, causing delamination between them

Machining of biocompatible materials: Recent advances

Machining of biocompatible materials is facing the fundamental challenges due to the specific material properties as well as the application requirements. Firstly, this paper presents a review of various materials which the medical industry needs to machine, then comments on the advances in the understanding of their specific cutting mechanisms. Finally it reviews the machining processes that the industry employs for different applications. This highlights the specific functional requirements that need to be considered when machining biocompatible materials and the associated machines and tooling. An analysis of the scientific and engineering challenges and opportunities related to this topic are presented

Remanufacturing and Advanced Machining Processes for New Materials and Components

"Remanufacturing and Advanced Machining Processes for Materials and Components presents current and emerging techniques for machining of new materials and restoration of components, as well as surface engineering methods aimed at prolonging the life of industrial systems. It examines contemporary machining processes for new materials, methods of protection and restoration of components, and smart machining processes. • Details a variety of advanced machining processes, new materials joining techniques, and methods to increase machining accuracy • Presents innovative methods for protection and restoration of components primarily from the perspective of remanufacturing and protective surface engineering • Discusses smart machining processes, including computer-integrated manufacturing and rapid prototyping, and smart materials • Provides a comprehensive summary of state-of-the-art in every section and a description of manufacturing methods • Describes the applications in recovery and enhancing purposes and identifies contemporary trends in industrial practice, emphasizing resource savings and performance prolongation for components and engineering systems The book is aimed at a range of readers, including graduate-level students, researchers, and engineers in mechanical, materials, and manufacturing engineering, especially those focused on resource savings, renovation, and failure prevention of components in engineering systems.

Remanufacturing and Advanced Machining Processes for New Materials and Components

Remanufacturing and Advanced Machining Processes for Materials and Components presents current and emerging techniques for machining of new materials and restoration of components, as well as surface engineering methods aimed at prolonging the life of industrial systems. It examines contemporary machining processes for new materials, methods of protection and restoration of components, and smart machining processes. • Details a variety of advanced machining processes, new materials joining techniques, and methods to increase machining accuracy • Presents innovative methods for protection and restoration of components primarily from the perspective of remanufacturing and protective surface engineering • Discusses smart machining processes, including computer-integrated manufacturing and rapid prototyping, and smart materials • Provides a comprehensive summary of state-of-the-art in every section and a description of manufacturing methods • Describes the applications in recovery and enhancing purposes and identifies contemporary trends in industrial practice, emphasizing resource savings and performance prolongation for components and engineering systems The book is aimed at a range of readers, including graduate-level students, researchers, and engineers in mechanical, materials, and manufacturing engineering, especially those focused on resource savings, renovation, and failure prevention of components in engineering systems

Remanufacturing and Advanced Machining Processes for New Materials and Components

"Remanufacturing and Advanced Machining Processes for Materials and Components presents current and emerging techniques for machining of new materials and restoration of components, as well as surface engineering methods aimed at prolonging the life of industrial systems. It examines contemporary machining processes for new materials, methods of protection and restoration of components, and smart machining processes. • Details a variety of advanced machining processes, new materials joining techniques, and methods to increase machining accuracy • Presents innovative methods for protection and restoration of components primarily from the perspective of remanufacturing and protective surface engineering • Discusses smart machining processes, including computer-integrated manufacturing and rapid prototyping, and smart materials • Provides a comprehensive summary of state-of-the-art in every section and a description of manufacturing methods • Describes the applications in recovery and enhancing purposes and identifies contemporary trends in industrial practice, emphasizing resource savings and performance prolongation for components and engineering systems The book is aimed at a range of readers, including graduate-level students, researchers, and engineers in mechanical, materials, and manufacturing engineering, especially those focused on resource savings, renovation, and failure prevention of components in engineering systems.

Remanufacturing and Advanced Machining Processes for New Materials and Components

Remanufacturing and Advanced Machining Processes for Materials and Components presents current and emerging techniques for machining of new materials and restoration of components, as well as surface engineering methods aimed at prolonging the life of industrial systems. It examines contemporary machining processes for new materials, methods of protection and restoration of components, and smart machining processes. • Details a variety of advanced machining processes, new materials joining techniques, and methods to increase machining accuracy • Presents innovative methods for protection and restoration of components primarily from the perspective of remanufacturing and protective surface engineering • Discusses smart machining processes, including computer-integrated manufacturing and rapid prototyping, and smart materials • Provides a comprehensive summary of state-of-the-art in every section and a description of manufacturing methods • Describes the applications in recovery and enhancing purposes and identifies contemporary trends in industrial practice, emphasizing resource savings and performance prolongation for components and engineering systems The book is aimed at a range of readers, including graduate-level students, researchers, and engineers in mechanical, materials, and manufacturing engineering, especially those focused on resource savings, renovation, and failure prevention of components in engineering systems