A new multi-view approach to characterize 3D chip morphology and properties in end milling titanium Ti-6Al-4V

TY - JOUR

T1 - A new multi-view approach to characterize 3D chip morphology and properties in end milling titanium Ti-6Al-4V

AU - Sun, J.

AU - Guo, Y. B.

N1 - Funding Information: The authors would like to thank The University of Alabama for financial support and the assistance of Drs. Andrew W. Warren, Mark Weaver and Mark E. Barkey for preparing samples and measurement.

PY - 2008/10

Y1 - 2008/10

N2 - End milling Ti-6Al-4V using a solid mill cutter has being widely used in aerospace, automotive, biomedical, and chemical industries. However, a comprehensive characterization of chip morphology and microstructural and mechanical behavior of machined chips is significantly lacking. A series of end milling experiments were conducted with flood coolant for this purpose. This research provides a new multi-view approach to fully characterize chip morphology including top surface, free surface, back surface, and cross-section surface. Each view of the 3-dimensional (3D) chip has shown different characteristics. The variation of chip dimensions with cutting parameters was also determined. The key findings of this study are: (a) the microstructural analysis shows that β phase experiences severe deformation and transformation to α phase in the second shear zone; (b) the phase transformation further leads to microhardness variations characterized by higher hardness at the surface and the lower hardness in the immediate subsurface; and (c) the shear band as well as the corner section of the chip shows increased hardness.

AB - End milling Ti-6Al-4V using a solid mill cutter has being widely used in aerospace, automotive, biomedical, and chemical industries. However, a comprehensive characterization of chip morphology and microstructural and mechanical behavior of machined chips is significantly lacking. A series of end milling experiments were conducted with flood coolant for this purpose. This research provides a new multi-view approach to fully characterize chip morphology including top surface, free surface, back surface, and cross-section surface. Each view of the 3-dimensional (3D) chip has shown different characteristics. The variation of chip dimensions with cutting parameters was also determined. The key findings of this study are: (a) the microstructural analysis shows that β phase experiences severe deformation and transformation to α phase in the second shear zone; (b) the phase transformation further leads to microhardness variations characterized by higher hardness at the surface and the lower hardness in the immediate subsurface; and (c) the shear band as well as the corner section of the chip shows increased hardness.

KW - Chip morphology

KW - End milling

KW - Microhardness

KW - Phase transformation

KW - Titanium alloys

UR - https://www.scopus.com/pages/publications/48549088120

UR - https://www.scopus.com/pages/publications/48549088120#tab=citedBy

U2 - 10.1016/j.ijmachtools.2008.04.002

DO - 10.1016/j.ijmachtools.2008.04.002

M3 - Article

SN - 0890-6955

VL - 48

SP - 1486

EP - 1494

JO - International Journal of Machine Tools and Manufacture

JF - International Journal of Machine Tools and Manufacture

IS - 12-13

ER -