Abstract
Titanium is attracting great attentions in aerospace and medical applications where high surface quality plays an important role in improving the product performance. For developing nano-precision machining technology for titanium, clarification of the nanometer-scale chip formation mechanism is essential. In this study, the surface formation mechanism of pure titanium in ultraprecision cutting tests using single-crystal diamond tools was investigated. The results demonstrated that decreasing undeformed chip thickness from the micrometer scale down to the nanometer scale had profound impacts on the shear angle, specific cutting force, and chip morphology. Chip tearing phenomenon occurred when undeformed chip thickness is smaller than a critical value (~ 100 nm), which significantly affected the chip morphology and machined surface integrity. In nanometer-scale cutting, tool feed mark is no longer a major reason of surface roughness; instead, material plucking, debris, scratches, and chip adhesion influenced the surface integrity. The high pressure generated in the nanometer-scale cutting caused a hardness increase in workpiece material and promoted workpiece material adhesion to the tool surface, as well as tool wear.
Similar content being viewed by others
References
Boyer R, Welsch G, Collings EW (1993) Materials properties handbook: titanium alloys. ASM international
Davim JP (2014) Machining of titanium alloys. doi: https://doi.org/10.1007/978-3-662-43902-9
Ezugwu EO, Wang ZM (1997) Titanium alloys and their machinability—a review. J Mater Process Technol 68:262–274. https://doi.org/10.1016/S0924-0136(96)00030-1
Machado AR, Wallbank J (1990) Machining of titanium and its alloys—a review. Proc Inst Mech Eng Part B J Eng Manuf 204:53–60. https://doi.org/10.1243/PIME_PROC_1990_204_047_02
Matthew J, Donachie J (2012) Titanium a technical guide, 2nd ed. ASM Int doi: https://doi.org/10.5772/1844
Yang X, Richard Liu C (1999) Machining titanium and its alloys. Mach Sci Technol 3:107–139. https://doi.org/10.1080/10940349908945686
Sun S, Brandt M, Dargusch MS (2009) Characteristics of cutting forces and chip formation in machining of titanium alloys. Int J Mach Tools Manuf 49:561–568. https://doi.org/10.1016/j.ijmachtools.2009.02.008
Calamaz M, Coupard D, Girot F (2008) A new material model for 2D numerical simulation of serrated chip formation when machining titanium alloy Ti–6Al–4V. Int J Mach Tools Manuf 48:275–288. https://doi.org/10.1016/j.ijmachtools.2007.10.014
Molinari A, Soldani X, Miguelez MH (2013) Adiabatic shear banding and scaling laws in chip formation with application to cutting of Ti-6Al-4V. J Mech Phys Solids 61:2331–2359. https://doi.org/10.1016/j.jmps.2013.05.006
Komanduri R, Von Turkovich BF (1981) New observations on the mechanism of chip formation when machining titanium alloys. Wear 69:179–188. https://doi.org/10.1016/0043-1648(81)90242-8
Komanduri R (1982) Some clarifications on the mechanics of chip formation when machining titanium alloys. Wear 76:15–34. https://doi.org/10.1016/0043-1648(82)90113-2
Ezugwu EO, Bonney J, Yamane Y (2003) An overview of the machinability of aeroengine alloys. J Mater Process Technol 134:233–253. https://doi.org/10.1016/S0924-0136(02)01042-7
Hasçalik A, Çaydaş U (2008) Optimization of turning parameters for surface roughness and tool life based on the Taguchi method. Int J Adv Manuf Technol 38:896–903. https://doi.org/10.1007/s00170-007-1147-0
Ramesh S, Karunamoorthy L, Palanikumar K (2008) Fuzzy modeling and analysis of machining parameters in machining titanium alloy. Mater Manuf Process 23:439–447. https://doi.org/10.1080/10426910801976676
Chauhan SR, Dass K (2012) Optimization of machining parameters in turning of titanium (grade-5) alloy using response surface methodology. Mater Manuf Process 27:531–537. https://doi.org/10.1080/10426914.2011.593236
Ribeiro MV, Moreira MRV, Ferreira JR (2003) Optimization of titanium alloy (6Al-4V) machining. J Mater Process Technol 143–144:458–463. https://doi.org/10.1016/S0924-0136(03)00457-6
Che-Haron CH (2001) Tool life and surface integrity in turning titanium alloy. J Mater Process Technol 118:231–237. https://doi.org/10.1016/S0924-0136(01)00926-8
Ulutan D, Ozel T (2011) Machining induced surface integrity in titanium and nickel alloys: a review. Int J Mach Tools Manuf 51:250–280. https://doi.org/10.1016/j.ijmachtools.2010.11.003
Che-Haron CH, Jawaid A (2005) The effect of machining on surface integrity of titanium alloy Ti-6% Al-4% V. J Mater Process Technol 166:188–192. https://doi.org/10.1016/j.jmatprotec.2004.08.012
Ginting A, Nouari M (2009) Surface integrity of dry machined titanium alloys. Int J Mach Tools Manuf 49:325–332. https://doi.org/10.1016/j.ijmachtools.2008.10.011
Zareena AR, Veldhuis SC (2012) Tool wear mechanisms and tool life enhancement in ultraprecision machining of titanium. J Mater Process Technol 212:560–570. https://doi.org/10.1016/j.jmatprotec.2011.10.014
Schneider F, Lohkamp R, Sousa FJP et al (2014) Analysis of the surface integrity in ultraprecision cutting of cp-titanium by investigating the chip formation. Procedia CIRP 13:55–60. https://doi.org/10.1016/j.procir.2014.04.010
Schneider F, Bischof R, Kirsch B et al (2016) Investigation of chip formation and surface integrity when micro-cutting cp-titanium with ultra-fine grain cemented carbide. Procedia CIRP 45:115–118. https://doi.org/10.1016/j.procir.2016.02.257
Ruibin X, Wu H (2016) Study on cutting mechanism of Ti6Al4V in ultraprecision machining. Int J Adv Manuf Technol 86:1311–1317. https://doi.org/10.1007/s00170-015-8304-7
Colafemina JP, Jasinevicius RG, Duduch JG (2007) Surface integrity of ultraprecision diamond turned Ti (commercially pure) and Ti alloy (Ti-6Al-4V). Proc Inst Mech Eng Part B J Eng Manuf 221:999–1006. https://doi.org/10.1243/09544054JEM798
Liu K, Li XP, Rahman M et al (2007) A study of the effect of tool cutting edge radius on ductile cutting of silicon wafers. Int J Adv Manuf Technol 32:631–637. https://doi.org/10.1007/s00170-005-0364-7
Heidari M, Yan J (2017) Ultraprecision surface flattening of porous silicon by diamond turning. Precis Eng 49:262–277. https://doi.org/10.1016/j.precisioneng.2017.02.015
Lalwani DI, Mehta NK, Jain PK (2008) Experimental investigations of cutting parameters influence on cutting forces and surface roughness in finish hard turning of MDN250 steel. J Mater Process Technol 206:167–179. https://doi.org/10.1016/j.jmatprotec.2007.12.018
de Oliveira FB, Rodrigues AR, Coelho RT, de Souza AF (2015) Size effect and minimum chip thickness in micromilling. Int J Mach Tools Manuf 89:39–54. https://doi.org/10.1016/j.ijmachtools.2014.11.001
Rao BC, Shin YC (1999) A comprehensive dynamic cutting force model for chatter prediction in turning. Int J Mach Tools Manuf 39:1631–1654. https://doi.org/10.1016/S0890-6955(99)00007-3
Chae J, Park SS, Freiheit T (2006) Investigation of micro-cutting operations. Int J Mach Tools Manuf 46:313–332. https://doi.org/10.1016/j.ijmachtools.2005.05.015
Klocke F (2011) Manufacturing processes 1: cutting. doi: https://doi.org/10.1007/978-3-642-11979-8
Grzesik W (2008) Advanced machining processes of metallic materials: theory, modelling and applications. Elsevier
Liu X, DeVor RE, Kapoor SG, Ehmann KF (2004) The mechanics of machining at the microscale: assessment of the current state of the science. J Manuf Sci Eng 126:666. https://doi.org/10.1115/1.1813469
Ikawa N, Shimada S, Tanaka H (1992) Minimum thickness of cut in micromachining. Nanotechnology 3:6–9. https://doi.org/10.1088/0957-4484/3/1/002
Lai X, Li H, Li C et al (2008) Modelling and analysis of micro scale milling considering size effect, micro cutter edge radius and minimum chip thickness. Int J Mach Tools Manuf 48:1–14. https://doi.org/10.1016/j.ijmachtools.2007.08.011
Malekian M, Mostofa MG, Park SS, Jun MBG (2012) Modeling of minimum uncut chip thickness in micro machining of aluminum. J Mater Process Technol 212:553–559. https://doi.org/10.1016/j.jmatprotec.2011.05.022
Zhanqiang L, Zhenyu S, Yi W (2013) Definition and determination of the minimum uncut chip thickness of microcutting. Int J Adv Manuf Technol 69:1219–1232. https://doi.org/10.1007/s00170-013-5109-4
Elkaseer A, Dimov S, Pham D, et al (2016) Material microstructure effects in micro-endmilling of Cu99.9E. Proc Inst Mech Eng Part B J Eng Manuf. doi: https://doi.org/10.1177/0954405416666898
Son SM, Lim HS, Ahn JH (2005) Effects of the friction coefficient on the minimum cutting thickness in micro cutting. Int J Mach Tools Manuf 45:529–535. https://doi.org/10.1016/j.ijmachtools.2004.09.001
Altintas Y (2012) Manufacturing automation: metal cutting mechanics, machine tool vibrations, and CNC design, second edn. Cambridge University Press, New York
Zlatin N, Field M (1973) Procedures and precautions in machining titanium alloys. In: Jaffee RI, Burte HM (eds) Titan Sci Technol. Springer US, Boston, MA, pp 489–504
Thornton AG, Wilks J (1979) Tool wear and solid state reactions during machining. Wear 53:165–187. https://doi.org/10.1016/0043-1648(79)90226-6
Kohlscheen J, Stock H-R, Mayr P (2002) Tailoring of diamond machinable coating materials. Precis Eng 26:175–182. https://doi.org/10.1016/S0141-6359(01)00109-X
Qian J, Pantea C, Voronin G, Zerda TW (2001) Partial graphitization of diamond crystals under high-pressure and high-temperature conditions. J Appl Phys 90:1632–1637. https://doi.org/10.1063/1.1382832
Liu H, Wang L, Wang A et al (1997) Preparation of nanometer size TiC particulate reinforcements in Ti matrix composites under high pressure. Nanostructured Mater 9:177–180. https://doi.org/10.1016/S0965-9773(97)00047-0
Mantle AL, Aspinwall DK (1997) Surface integrity and fatigue life of turned gamma titanium aluminide. J Mater Process Technol 72:413–420. https://doi.org/10.1016/S0924-0136(97)00204-5
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Heidari, M., Yan, J. Nanometer-scale chip formation and surface integrity of pure titanium in diamond turning. Int J Adv Manuf Technol 95, 479–492 (2018). https://doi.org/10.1007/s00170-017-1185-1
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-017-1185-1