Abstract
Titanium and titanium alloys such as Ti-6Al-4V are generally considered as difficult-to-machine materials. This is mainly due to their high chemical reactivity, poor thermal conductivity, and high strength, which is maintained at elevated temperatures. As a result, the cutting tool is exposed to rather extreme contact conditions resulting in plastic deformation and wear. In the present work, the mechanisms behind the crater and flank wear of uncoated cemented carbide inserts in the turning of Ti6Al4V are characterized using high-resolution scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and high-resolution Auger electron spectroscopy (AES).The results show that, for combinations of low cutting speeds and feeds, crater and flank wear were found to be controlled by an attrition wear mechanism, while for combinations of medium to high cutting speeds and feeds, a diffusion wear mechanism was found to control the wear. For the latter combinations, high-resolution SEM and AES analysis reveal the formation of an approximately 100 nm thick carbon-depleted tungsten carbide (WC)-layer at the cemented carbide/Ti6Al4V interface due to the diffusion of carbon into the adhered build-up layers of work material on the rake and flank surfaces.
Highlights
In machining, tribochemical and mechanical properties of the work and tool materials and the cutting conditions affect the tool wear, which, in turn, affect the efficiency of the machining operation and the surface roughness of the machined surface
The contact conditions occurring at the edge depression and micro or macro fracture of the cutting edge region occurs [29,30,31,32], and some tool crater/chip and tool flank/work material interfaces are discussed and interpreted as the wear authors [23,33] believe that 60 m/min is the cutting speed which higher than that limit the lifetime of characteristics of the crater and flank wear respectively
The results of the present study indicate that both crater and flank wear are controlled by mainly two different wear mechanisms
Summary
Tribochemical and mechanical properties of the work and tool materials and the cutting conditions (cutting speed, cutting feed, etc.) affect the tool wear, which, in turn, affect the efficiency of the machining operation and the surface roughness of the machined surface. Flank wear is controlled by a mechanical wear mechanism, e.g., abrasion, while crater wear, due to the higher temperatures on the rake face, is controlled by a tribochemical wear mechanism, e.g., diffusion wear or solution wear The former mechanism has typically been considered to have a wear rate proportional to sliding velocity after a fundamental model by Archard [3]. Β alloyOn which the most employed alloy in aerospace applications elevated temperature the isother hand, Ti6Al4V titanium shows machining challenges which is due to the corrosion resistance,ofthe high strength-to-weight ratio and the fatigue properties at elevated mainly due to a combination properties including: temperature [10,11].
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