Top

The International Journal of Advanced Manufacturing Technology

Published in:

04-12-2019 | ORIGINAL ARTICLE

Effect of process parameters on chip formation during vibration-assisted drilling of Ti6Al4V

Authors: R. Hussein, A. Sadek, M. A. Elbestawi, M.H. Attia

Published in: The International Journal of Advanced Manufacturing Technology | Issue 3-4/2020

Activate our intelligent search to find suitable subject content or patents.

search-config

AI-assisted search

Off

Abstract

Vibration-assisted drilling (VAD) of Ti6Al4V is typically used in the aerospace industry to enhance the performance of the machining process. A mix of continuous and saw-tooth chip formation is associated with VAD of Ti6Al4V. In this paper, a comprehensive experimental study is developed to examine the effect of process parameters on the dominant chip formation mechanisms and the associated effects on the thrust forces and machined surface finish. The results indicate a significant change of the chips free surface produced by VAD. The kinematics of VAD showed a direct relation between the VAD amplitude and the effective rake angle. In agreement with the theory of saw-tooth formation due to cyclic crack formation, the scanning electron microscopy (SEM) examination showed a gross crack (GC) and micro crack (MC) along the shear plane. The GC increased from 20 μm for conventional drilling to 224 μm for VAD at the highest amplitude. Moreover, increasing the VAD amplitude to 160 μm showed an obvious enhancement of the machined surface finish. In addition, the study presents the influence of VAD on the tool wear mechanisms through the composition analysis of the chips machined surface using Energy Dispersion X-ray Spectroscopy (EDS).

previous article Distributed automated manufacturing of pluripotent stem cell products

next article A study of viscosity and thermal conductivity of vegetable oils as base cutting fluids for minimum quantity lubrication machining of difficult-to-cut metals

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

über 102.000 Bücher
über 537 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Finance + Banking
Management + Führung
Marketing + Vertrieb
Maschinenbau + Werkstoffe
Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

inform now

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

über 67.000 Bücher
über 390 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Maschinenbau + Werkstoffe

Jetzt Wissensvorsprung sichern!

inform now

Park K-H, Beal A, Kwon P, Lantrip J (2011) Tool wear in drilling of composite/titanium stacks using carbide and polycrystalline diamond tools. Wear 271:2826–2835

Dornfeld D, Kim J, Dechow H, Hewson J, Chen L (1999) Drilling burr formation in titanium alloy, Ti-6AI-4V. CIRP Annals-Manufacturing Technology 48:73–76

Li Z, Zhang D, Jiang X, Qin W, Geng D (2017) Study on rotary ultrasonic-assisted drilling of titanium alloys (Ti6Al4V) using 8-facet drill under no cooling condition. Int J Adv Manuf Technol 90:3249–3264

Cantero JL, Tardío MM, Canteli JA, Marcos M, Miguélez MH (2005) Dry drilling of alloy Ti–6Al–4V. Int J Mach Tools Manuf 45:1246–1255 2005/09/01/

Przestacki D, Majchrowski R, Marciniak-Podsadna L (2016) Experimental research of surface roughness and surface texture after laser cladding. Appl Surf Sci 388:420–423

Przestacki D, Chwalczuk T, Wojciechowski S (2017) The study on minimum uncut chip thickness and cutting forces during laser-assisted turning of WC/NiCr clad layers. Int J Adv Manuf Technol 91:3887–3898

Bartkowska A, Pertek A, Popławski M, Bartkowski D, Przestacki D, Miklaszewski A (2015) Effect of laser modification of B–Ni complex layer on wear resistance and microhardness. Opt Laser Technol 72:116–124

Chang SS, Bone GM (2005) Burr size reduction in drilling by ultrasonic assistance. Robot Comput Integr Manuf 21:442–450

Hussein R, Sadek A, Elbestawi MA, Attia MH (2019) Surface and microstructure characterization of low-frequency vibration-assisted drilling of Ti6Al4V. Int J Adv Manuf Technol 103:1443–1457

10.

Pereira RBD, Branda LC, de Paiva AP, Ferreira JR, Davim JP (2017) A review of helical milling process. Int J Mach Tools Manuf 120:27–48 2017/09/01/

11.

M’Saoubi R, Axinte D, Soo SL, Nobel C, Attia H, Kappmeyer G et al (2015) High performance cutting of advanced aerospace alloys and composite materials. CIRP Ann 64:557–580

12.

Pecat O, Meyer I (2013). Low frequency vibration assisted drilling of aluminium alloys. Adv Mater Res 769:131-138.

13.

Hussein R, Sadek A, Elbestawi MA, Attia M (2018) Low-frequency vibration-assisted drilling of hybrid CFRP/Ti6Al4V stacked material. Int J Adv Manuf Technol 98:2801–2817

14.

Komanduri R (1982) Some clarifications on the mechanics of chip formation when machining titanium alloys. Wear 76:15–34

15.

Komanduri R, Von Turkovich B (1981) New observations on the mechanism of chip formation when machining titanium alloys. Wear 69:179–188

16.

Vyas A, Shaw M (1999) Mechanics of saw-tooth chip formation in metal cutting. J Manuf Sci Eng 121:163–172

17.

Barry J, Byrne G, Lennon D (2001) Observations on chip formation and acoustic emission in machining Ti–6Al–4V alloy. Int J Mach Tools Manuf 41:1055–1070

18.

Choudhury I, El-Baradie M (1998) Machinability of nickel-base super alloys: a general review. J Mater Process Technol 77:278–284

19.

Barry J, Byrne G (2001) Study on acoustic emission in machining hardened steels Part 1: acoustic emission during saw-tooth chip formation. Proc IMechE B J Eng Manuf 215:1549–1559

20.

Elbestawi M, Srivastava A, El-Wardany T (1996) A model for chip formation during machining of hardened steel. CIRP Ann 45:71–76

21.

El-Wardany T, Kishawy H, Elbestawi M (2000) Surface integrity of die material in high speed hard machining, Part 1: Micrographical analysis. J Manuf Sci Eng 122:620–631

22.

Nakayama K (1977) On the formation of “saw-toothed chip” in metal cutting. J Japan Soc Prec Eng 43:117–122

23.

E. A. H. Kishawy1998, Chip formation and surface integrity in high speed machining of hardened steel.

24.

Shaw MC, Cookson J (2005) Metal cutting principles vol. 2. Oxford University Press, New York

25.

Recht R (1964) Catastrophic thermoplastic shear. J Appl Mech 31:189–193

26.

Li R, Riester L, Watkins TR, Blau PJ, Shih AJ (2008) Metallurgical analysis and nanoindentation characterization of Ti–6Al–4V workpiece and chips in high-throughput drilling. Mater Sci Eng A 472:115–124

27.

Wan Z, Zhu Y, Liu H, Tang Y (2012) Microstructure evolution of adiabatic shear bands and mechanisms of saw-tooth chip formation in machining Ti6Al4V. Mater Sci Eng A 531:155–163

28.

Sun S, Brandt M, Dargusch MS (2017) Effect of tool wear on chip formation during dry machining of Ti-6Al-4V alloy, part 1: effect of gradual tool wear evolution. Proc IMechE B J Eng Manuf 231:1559–1574

29.

Sih, GC (1974) Surface layer energy and strain energy density for a blunted crack or notch, Prospect of Fracture Mechanics, edited by GC Sih, HC van Elst and D Broek. pp. 85–102

30.

Iqbal S, Mativenga P, Sheikh M (2009) A comparative study of the tool–chip contact length in turning of two engineering alloys for a wide range of cutting speeds. Int J Adv Manuf Technol 42:30

31.

Bermingham M, Kirsch J, Sun S, Palanisamy S, Dargusch M (2011) New observations on tool life, cutting forces and chip morphology in cryogenic machining Ti-6Al-4V. Int J Mach Tools Manuf 51:500–511

32.

Bayoumi A, Xie J (1995) Some metallurgical aspects of chip formation in cutting Ti-6 wt.% Al-4 wt.% V alloy. Mater Sci Eng A 190:173–180

33.

Sánchez Y, Trujillo F, Bermudo Gamboa C, Sevilla L (2018) Experimental parametric relationships for chip geometry in dry machining of the Ti6Al4V alloy. Materials (Basel) 11:1260

34.

Daymi A, Boujelbene M, Salem SB, Sassi BH, Torbaty S (2009) Effect of the cutting speed on the chip morphology and the cutting forces. Archives of Computational Materials Science and Surface Engineering 1:77–83

35.

Davies MA, Chou Y, Evans CJ (1996) On chip morphology, tool wear and cutting mechanics in finish hard turning. CIRP Ann 45:77–82

36.

Yang H, Chen Y, Xu J, Ladonne M, Lonfier J, Fu Y (2019) Tool wear mechanism in low-frequency vibration–assisted drilling of CFRP/Ti stacks and its individual layer. Int J Adv Manuf Technol 104:1–13

37.

A. Sadek, Vibration assisted drilling of multidirectional fiber reinforced polymer laminates, Ph.D. Thesis, McGill University Libraries, 2014.

38.

Zhao W, Gong L, Ren F, Li L, Xu Q, Khan AM (2018) Experimental study on chip deformation of Ti-6Al-4V titanium alloy in cryogenic cutting. Int J Adv Manuf Technol 96:4021–4027

39.

Brinksmeier E, Pecat O, Rentsch R (2015) Quantitative analysis of chip extraction in drilling of Ti 6 Al 4V. CIRP Annals-Manufacturing Technology 64:93–96

40.

Sun S, Brandt M, Dargusch M (2009) Characteristics of cutting forces and chip formation in machining of titanium alloys. Int J Mach Tools Manuf 49:561–568

41.

Dearnley P, Grearson A (1986) Evaluation of principal wear mechanisms of cemented carbides and ceramics used for machining titanium alloy IMI 318. Mater Sci Technol 2:47–58

42.

Hartung PD, Kramer B, Von Turkovich B (1982) Tool wear in titanium machining. CIRP Ann 31:75–80

43.

Stephenson DA, Agapiou JS (2016) Metal cutting theory and practice. CRC press, Boca Raton

44.

Santhanam A, Tierney P, Hunt J (1990) Cemented carbides, ASM International, Metals Handbook. Tenth 2:950–977

45.

Sun S, Brandt M, Dargusch MS (2017) Effect of tool wear on chip formation during dry machining of Ti-6Al-4V alloy, part 2: effect of tool failure modes. Proc IMechE B J Eng Manuf 231:1575–1586

Title: Effect of process parameters on chip formation during vibration-assisted drilling of Ti6Al4V
Authors: R. Hussein
A. Sadek
M. A. Elbestawi
M.H. Attia
Publication date: 04-12-2019
Publisher: Springer London
Published in: The International Journal of Advanced Manufacturing Technology / Issue 3-4/2020
Print ISSN: 0268-3768
Electronic ISSN: 1433-3015
DOI: https://doi.org/10.1007/s00170-019-04627-9

Springer Professional

Abstract

Please log in to get access to your license.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Springer Professional "Technik"

Other articles of this Issue 3-4/2020

Experimental investigation on mechanical drilling of a newly developed CFRP/Al co-cured material

Investigation of machining and wear performance of various diamond micro-grinding tools

Technical-economic evaluation of abrasive recycling in the suspension fine jet process chain

Sustainability and environmental impact of fused deposition modelling (FDM) technologies

High-speed milling of CFRP composites: a progressive damage model of cutting force

Comparative tool wear and hole quality investigation in drilling of aerospace grade T800 CFRP using different external cooling lubricants

Premium Partners