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Title: Infrared measurement of the temperature at the tool–chip interface while machining Ti–6Al–4V

Authors:
; ; ; ; ;
Publication Date:
Sponsoring Org.:
USDOE
OSTI Identifier:
1397468
Resource Type:
Journal Article: Publisher's Accepted Manuscript
Journal Name:
Journal of Materials Processing Technology
Additional Journal Information:
Journal Volume: 243; Journal Issue: C; Related Information: CHORUS Timestamp: 2017-10-04 21:23:13; Journal ID: ISSN 0924-0136
Publisher:
Elsevier
Country of Publication:
Switzerland
Language:
English

Citation Formats

Heigel, J. C., Whitenton, E., Lane, B., Donmez, M. A., Madhavan, V., and Moscoso-Kingsley, W. Infrared measurement of the temperature at the tool–chip interface while machining Ti–6Al–4V. Switzerland: N. p., 2017. Web. doi:10.1016/j.jmatprotec.2016.11.026.
Heigel, J. C., Whitenton, E., Lane, B., Donmez, M. A., Madhavan, V., & Moscoso-Kingsley, W. Infrared measurement of the temperature at the tool–chip interface while machining Ti–6Al–4V. Switzerland. doi:10.1016/j.jmatprotec.2016.11.026.
Heigel, J. C., Whitenton, E., Lane, B., Donmez, M. A., Madhavan, V., and Moscoso-Kingsley, W. Mon . "Infrared measurement of the temperature at the tool–chip interface while machining Ti–6Al–4V". Switzerland. doi:10.1016/j.jmatprotec.2016.11.026.
@article{osti_1397468,
title = {Infrared measurement of the temperature at the tool–chip interface while machining Ti–6Al–4V},
author = {Heigel, J. C. and Whitenton, E. and Lane, B. and Donmez, M. A. and Madhavan, V. and Moscoso-Kingsley, W.},
abstractNote = {},
doi = {10.1016/j.jmatprotec.2016.11.026},
journal = {Journal of Materials Processing Technology},
number = C,
volume = 243,
place = {Switzerland},
year = {Mon May 01 00:00:00 EDT 2017},
month = {Mon May 01 00:00:00 EDT 2017}
}

Journal Article:
Free Publicly Available Full Text
Publisher's Version of Record at 10.1016/j.jmatprotec.2016.11.026

Citation Metrics:
Cited by: 2works
Citation information provided by
Web of Science

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  • Mechanical behaviors at 538 C, including tensile and creep properties, were investigated for both the Ti-6Al-4V alloy and the Ti-6Al-4V composite reinforced with 10 wt pct TiC particulates fabricated by cold and hot isostatic pressing (CHIP). It was shown that the yield strength (YS) and ultimate tensile strength (UTS) of the composite were greater than those of the matrix alloy at the strain rates ranging from approximately 10{sup {minus}5} to 10{sup {minus}3} s{sup {minus}1}. However, the elongation of the composite material was substantially lower than that of the matrix alloy. The creep resistance of the composite was superior to thatmore » of the matrix alloy. The data of minimum creep strain rate vs applied stress for the composite can be fit to a power-law equation, and the stress exponent values of 5 and 8 were obtained for applied stress ranges of 103 to 232 MPa and 232 to 379 MPa, respectively. The damage mechanisms were different for the matrix alloy and the composite, as demonstrated by the scanning electron microscopy (SEM) observation of fracture surfaces and the optical microscopy examination of the regions adjacent to the fracture surface. The tensile-tested matrix alloy showed dimpled fracture, while the creep-tested matrix alloy exhibited preferentially interlath and intercolony cracking. The failure of the tensile-tested and creep-tested composite material was controlled by the cleavage failure of the particulates, which was followed by the ductile fracture of the matrix.« less
  • Titanium alloys offer superb properties in strength, corrosion resistance and biocompatibility and are commonly utilized in medical devices and implants. Micro-end milling process is a direct and rapid fabrication method for manufacturing medical devices and implants in titanium alloys. Process performance and quality depend upon an understanding of the relationship between cutting parameters and forces and resultant tool deflections to avoid tool breakage. For this purpose, FE simulations of chip formation during micro-end milling of Ti-6Al-4V alloy with an ultra-fine grain solid carbide two-flute micro-end mill are investigated using DEFORM software.At first, specific forces in tangential and radial directions ofmore » cutting during micro-end milling for varying feed advance and rotational speeds have been determined using designed FE simulations for chip formation process. Later, these forces are applied to the micro-end mill geometry along the axial depth of cut in 3D analysis of ABAQUS. Consequently, 3D distributions for tool deflections and von Misses stress are determined. These analyses will yield in establishing integrated multi-physics process models for high performance micro-end milling and a leap-forward to process improvements.« less
  • The ability of a fiber-matrix interface to support a transverse load is typically evaluated in straight-sided composite specimens where a stress singularity exists at the free surface of the interface. This stress singularity is often the cause of crack initiation and debonding during transverse loading. In order to develop a fundamental understanding of the transverse behavior of the fiber-matrix interface, it is necessary to alter the crack initiation site from the free surface to an internal location. To achieve this objective, a cross-shaped specimen has been recently developed. In this study, based on the experimentally observed onset of nonlinearity inmore » the stress-strain curve of these specimens and finite element analysis, the bond strength of the SCS-6/Ti-6Al-4V interface was determined to be 115 MPa. The micromechanical behavior of these specimens under transverse loading was examined by finite element analysis using this interface bond strength value and compared with experimental observations. Results demonstrate that the proposed geometry was successful in suppressing debonding at the surface and altering it to an internal event. The results from numerical analysis correlated well with the experimental stress-strain curve and several simple analytical models. In an attempt to identify the true bond strength and the interface failure criterion, the present study suggests that if failure initiates under tensile radial stresses, then the normal bond strength of the SCS-6/Ti-6Al-4V composites is about 115 MPa; under shear failure, the tangential shear strength of the interface is about 180 MPa.« less
  • During transverse loading of continuous fiber-reinforced composites, large tangential shear stresses develop at the interface at about 45{degree} to the loading axis. These shear stresses may initiate interface failure and frictional sliding, increasing the load in the matrix and lowering the applied stress to cause normal fiber-matrix separation. In the present study, an attempt has been made to measure the tangential shear strength of the interface for single fiber SiC/Ti-6Al-4V composites with varying interfaces using torsion testing and finite element stress analysis. An energy based fracture mechanics approach was developed to predict the micro-mechanical response of the composite to torsionalmore » loading following interface crack initiation. The fracture mechanics analysis suggests that a non-linearity would appear in the strain versus angle of twist curve once debonding initiates. Based on the onset of non-linearity and finite element stress analysis, the tangential shear strength for SCs-6/Ti-6Al-4V interface (carbon-rich coated) was estimated at 50 MPa; that for the SCS-0/Ti-6Al-4V interface (uncoated) was greater than 80 MPa, and that for the Ac1/Ti-6Al-4V interface (carbon coated) was about 40 MPa. Comparison of these results with experimental observations and finite element analysis of transverse tension tests indicates that failure in SCs-6/Ti-6Al-4V and AC1/Ti-6Al-4V composites is initiated by tangential shear failure of the interface. In SCS-0/Ti-6Al-4V composites, the results are not conclusive.« less