Wear mechanisms analysis for turning Ti-6Al-4V-towards the development of suitable tool coatings

International Journal of Advanced Manufacturing Technology

Volumn 58, Issue 5-8, 2012, Pages 479-493

  Jaffery, Syed H Imran ^a   Mativenga, Paul T ^b  

^a NATIONAL UNIVERSITY OF SCIENCES AND TECHNOLOGY   (Pakistan)

^b UNIVERSITY OF MANCHESTER   (United Kingdom)

Author keywords

Machining; Ti6Al4V; Titanium; Tool coatings; Wear mechanisms

Indexed keywords

EXCELLENT CORROSION RESISTANCES; HIGH STRENGTH; LOW DENSITY; MACHINING CONDITIONS; TI-6AL-4V; TI-6AL-4V ALLOY; TITANIUM-BASED ALLOYS; TOOL COATING; TOOL COATINGS; TOOL WEAR RATE; WEAR MECHANISMS;

AEROSPACE APPLICATIONS; ALLOYS; ALUMINUM; CERIUM ALLOYS; COATINGS; CORROSION RESISTANCE; HEAT RESISTANCE; MACHINING; TITANIUM; TRIBOLOGY; VANADIUM; WEAR OF MATERIALS;

TITANIUM ALLOYS;

EID: 84855998124     PISSN: 02683768     EISSN: 14333015     Source Type: Journal    
DOI: 10.1007/s00170-011-3427-y     Document Type: Article

References (66)

1. Lutjering G, Williams JC (2003) Titanium. Springer, Berlin
2. Kornilov II (1954) Solubility of the elements in titanium. Russ Chem Bull 3(3):329-335
3. Weiss V (1963) Aerospace structural metals handbook, vol 2. Syracuse Universiyt Press, Syracuse
4. Amin AKMN, Ismail AF, Khairusshima MKN (2007) Effectiveness of uncoated WC-Co and PCD inserts in end milling of titanium alloy-Ti-6Al-4V. J Mater Process Technol 192-193:147-158 (Pubitemid 47193231)
5. Teoh SH (2004) Engineering materials for biomedical applications. World Scientific Publishing Co. Pte. Ltd, Singapore
6. Hughes J, Sharman A, Ridgway K (2004) The effect of tool edge preparation on tool life and workpiece surface integrity. Proceedings of the Institution of Mechanical Engineers, Part B. J Eng Manuf 218(9):1113-1123
7. Boyer RR (1996) An overview on the use of titanium in the aerospace industry. Mater Sci Eng 213(1-2):103-114 (Pubitemid 126394525)
8. Jaffery SI, Mativenga PT (2009) Assessment of the machinability of Ti-6Al-4V alloy using the wear map approach. Int J Adv Manuf Technol 40:687-696
9. Waterman NA, Ashby MF (eds) (1991) Elsevier Material Selector, vol. 2. Elsevier, Barking (Essex, UK)
10. Hughes JI, Sharman ARC, Ridgway K (2006) The effect of cutting tool material and edge geometry on tool life and workpiece surface integrity. Proceedings of the Institution of Mechanical Engineers, Part B. J Eng Manuf 220(B):93-107 (Pubitemid 46594282)
11. de Lacalle Lopez et al (2000) Advanced cutting conditions for the milling of aeronautical alloys. J Mater Process Technol 100:1-11 (Pubitemid 30576166)
12. Insperger T et al (2003) Stability of up-milling and down-milling, part 1: alternative analytical methods. Int JMachine Tool Manuf 43:25-34 (Pubitemid 35385282)
13. Komanduri R, Reed JWR (1983) Evaluation of carbide grades and a new cutting geometry for machining titanium alloys. Wear 92:113-123 (Pubitemid 14544949)
14. Kramer BM, Viens D, Chin S (1993) Theoretical consideration of rare earth metal compounds as tool materials for titanium machining. CIRP Ann Manuf Technol 42(1):111-114 (Pubitemid 23679076)
15. Ezugwu EO, Wang ZM (1997) Titanium alloys and their machinability-a review. J Mater Process Technol 68:262-274 (Pubitemid 127393463)
16. Barrow G (1972) Wear of cutting tools. Tribology 5:22-30
17. Venugopal KA, Paul S, Chattopadhyay AB (2007) Growth of tool wear in turning of Ti-6Al-4V alloy under cryogenic cooling. Wear 62:1071-1078 (Pubitemid 46496997)
18. Taylor J (1962) The tool wear-time relationship in metal cutting. Int J Mach Tool Des Res 2:119-152
19. Cselle T, Barimani A (1995) Today's applications and future developments of coatings for drills and rotating cutting tools. Surf Coat Technol 76-77:712-718, Part 2
20. Calamaz M et al (2006) Damage modes of straight tungsten carbide in dry machining of titanium alloy TA6V. J Phys Proc 134:1265-1271 (Pubitemid 44681799)
21. Dearnley PA, Grearson AN (1986) Evaluation of principal wear mechanisms of cemented carbides and ceramics used for machining titanium alloy IMI318. Mater Sci Technol 2(1):47-58 (Pubitemid 16545587)
22. Komanduri R (1982) Some clarifications on the mechanism of chip formation when machining titanium alloys. Wear 76:15-34 (Pubitemid 12524371)
23. Narutaki N et al (1983) Study on machining of titanium alloys. CIRP Ann Manuf Technol 32(1):65-69
24. Ribeiro MV, Moreira MRV, Ferreira JR (2003) Optimization of titanium alloy (6Al-4V) machining. J Mater Process Technol 143-144:458-463
25. Shaw MC (2005) Metal cutting principles. Oxford University Press, Tempe, Arizona
26. Hartung PD, Kramer BM, von Turkovich BF (1982) Tool wear in titanium machining. CIRP Ann Manuf Technol 31(1):75-80
27. Wang ZM, Ezugwu EO, Gupta A (1998) Evaluation of a self-propelled rotary tool in the machining of aerospace materials. Tribol Trans 41(2):289-295
28. Ezugwu EO et al (2005) The effect of argon-enriched environment in high-speed machining of titanium alloy. Tribol Trans 48(1):18-23
29. Ezugwu EO et al (2009) High productivity rough turning of Ti-6Al-4V alloy, with flood and high-pressure cooling. Tribol Trans 52(3):395-400
30. Elmagrabi N et al (2008) High speed milling of Ti-6Al-4V using coated carbide tools. Eur J Sci Res 22(2):153-162
31. Che Haron CH, Ginting A, Arshad H (2007) Performance of alloyed uncoated and CVD-coated carbide tools in dry milling of titanium alloy Ti-6242S. J Mater Process Technol 185(1-3):77-82
32. Sharif S, Rahim EA (2007) Performance of coated- and uncoated-carbide tools when drilling titanium alloy-Ti-6Al4V. J Mater Process Technol 185(1-3):72-76 (Pubitemid 46283394)
33. Ginting A, Nouari M (2006) Experimental and numerical studies on the performance of alloyed carbide tool in dry milling of aerospace material. Int J Mach Tool Manuf 46(7-8):758-768
34. Nouari M, Ginting A (2006) Wear characteristics and performance of multi-layer CVD-coated alloyed carbide tool in dry end milling of titanium alloy. Surf Coat Technol 200(18-19):5663-5676
35. Dearnley PA, Schellewald M, Dahm KL (2005) Characterisation and wear response of metal-boride coated WC-Co. Wear 259(7-12):861-869 (Pubitemid 40762958)
36. Cherukuri R, Molian P (2003) Lathe turning of titanium using pulsed laser deposited, ultra-hard boride coatings of carbide inserts. Mach Sci Technol 7(1):119-135
37. Fitzsimmons M, Sarin VK (2001) Development of CVD WC Co coatings. Surf Coat Technol 137:158-163 (Pubitemid 32337767)
38. Nabhani F (2001) Wear mechanisms of ultra-hard cutting tools materials. J Mater Process Technol 115(3):402-412 (Pubitemid 32935691)
39. Zareena AR, Rahman M, Wong YS (2005) Binderless CBN tools, a breakthrough for machining titanium alloys. J Manuf Sci Eng 127:277-279 (Pubitemid 40718381)
40. Ezugwu EO et al (2005) Evaluation of the performance of CBN tools when turning Ti-6Al-4V alloy with high pressure coolant supplies. Int J Mach Tool Manuf 45:1009-1014 (Pubitemid 40339660)
41. Wang ZM, Ezugwu EO (1997) Performance of PVD-coated carbide tools when machining Ti-6Al-4V. Tribol Trans 40(1):81-86
42. Ezugwu EO, Wang ZM, Machado AR (2000) Wear of coated carbide tools when machining nickel (inconel 718) and titanium base (Ti-6A1-4V) alloys. Tribol Trans 43(2):263-268 (Pubitemid 30322962)
43. Kishawy HA, Becze CE, McIntosh DG (2004) Tool performance and attainable surface quality during the machining of aerospace alloys using self-propelled rotary tools. J Mater Process Technol 152:266-271
44. Corduan N et al (2003) Wear mechanisms of new tool materials for Ti-6AI-4V high performance machining. CIRP Ann Manuf Technol 52(1):73-76
45. Bhaumik SK, Divakar C, Singh AK (1995) Machining Ti-6Al-4V alloy with a wBN-cBN composite tool. Mater Des 16(4):221-226
46. Jawaid A, Sharif S, Koksal S (2000) Evaluation of wear mechanisms of coated carbide tools when face milling titanium alloy. J Mater Process Technol 99:266-274 (Pubitemid 30557736)
47. xN (x∈=∈0.5 and 0.67) PVD coatings in milling operations. Surf Coat Technol 201(8):4585-4593 (Pubitemid 44895136)
48. Ezugwu EO (2004) High speed machining of aero-engine alloys. J Braz Soc Mech Sci Eng 1:1-11, XXVI
49. Jaffery SI, Mativenga PT (2009) Study of the use of wear maps for assessing machining performance. Proceedings of the Institution of Mechanical Engineers, Part B. J Eng Manuf 223(9):1097-1105
50. Pierson HO (1996) Handbook of refractory carbides and nitrides. William Andrew Publishing, Westwood, NJ
51. Akbar F, Mativenga PT, Sheikh MA (2009) On the heat partition properties of (Ti, Al)N compared with TiN coating in high-speed machining. Proceedings of the Institution of Mechanical Engineers, Part B. J Eng Manuf 223(4):363-375
52. Kalss W et al (2006) Modern coatings in high performance cutting applications. Int J Refract Met Hard Mater 24(5):399-404
53. Yen Y-C et al (2004) Computer simulation of orthogonal cutting using a tool with multiple coatings. Mach Sci Technol 8(2):305-326
54. 3Al. Poroshkovaya Metall 8(44):43-48
55. Auerkari P (1996) Mechanical and physical properties of engineering alumina ceramics. Technical Research Center of Finland (VTT), Finland
56. Mizuta N et al (2008) Titanium aluminide coating on titanium surface using three-dimensional microwelder. Mater Sci Eng 492(1-2):199-204
57. 3Al/TiAl interface by first-principles calculations. Scripta Metallurgica et Materialia 33(6):885-891
58. Pierson HO (1999) Handbook of chemical vapor deposition: principles, technology and applications. William Andrew Publishing, Norwich, 458 pages
59. Committee on Coatings, National Materials Advisory Board, Division of Engineering, National Research Council (1970) High-temperature oxidation-resistant coatings. National Academy of Sciences National Academy of Engineering, Washington DC
60. Chang Y-Y, Yang S-J, Wang D-Y (2006) Structural and mechanical properties of AlTiN/CrN coatings synthesized by a cathodic-arc deposition process. Surf Coat Technol 201(7):4209-4214 (Pubitemid 44801298)
61. Le Bourhis E et al (2009) Mechanical properties of hard AlCrN-based coated substrates. Surf Coat Technol 203(19):2961-2968
62. Mo JL et al (2007) Comparison of tribological behaviours of AlCrN and TiAlN coatings: deposited by physical vapor deposition. Wear 263(7-12):1423-1429 (Pubitemid 47287689)
63. XN films. Surf Coat Technol 165(2):163-167 (Pubitemid 36073076)
64. Tool-life testing with single-point turning tools (1993) International Organization for Standardization. Switzerland, Geneva
65. Lim SC et al (1996) Wear maps for some uncoated cutting tools. Tribotest 3(1):67-88
66. Komanduri R, Turkovich BFV (1981) New observations on the mechanism of chip formation when machining titanium alloys. Wear 69:179-188