Abstract
The TiC particles in titanium metal matrix composites (TiMMCs) make them difficult to machine. As a specific MMC, it is legitimate to wonder if the cutting mechanisms of TiMMCs are the same as or similar to those of MMCs. For this purpose, the tool wear mechanisms for turning, milling, and grinding are reviewed in this paper and compared with those for other MMCs. In addition, the chip formation and morphology, the material removal mechanism and surface quality are discussed for the different machining processes and examined thoroughly. Comparisons of the machining mechanisms between the TiMMCs and MMCs indicate that the findings for other MMCs should not be taken for granted for TiMMCs for the machining processes reviewed. The increase in cutting speed leads to a decrease in roughness value during grinding and an increase of the tool life during turning. Unconventional machining such as laser-assisted turning is effective to increase tool life. Under certain conditions, a “wear shield” was observed during the early stages of tool wear during turning, thereby increasing tool life considerably. The studies carried out on milling showed that the cutting parameters affecting surface roughness and tool wear are dependent on the tool material. The high temperatures and high shears that occur during machining lead to microstructural changes in the workpiece during grinding, and in the chips during turning. The adiabatic shear band (ASB) of the chips is the seat of the sub-grains’ formation. Finally, the cutting speed and lubrication influenced dust emission during turning but more studies are needed to validate this finding. For the milling or grinding, there are major areas to be considered for thoroughly understanding the machining behavior of TiMMCs (tool wear mechanisms, chip formation, dust emission, etc.).
Highlights
Titanium and its alloys have been the subject of significant research interest in different fields
Titanium metal matrix composites (TiMMCs) are made of a titanium alloy matrix reinforced with fibers, particles, or whiskers [3] which provide them exceptional properties such as a high specific modulus, high specific strength, high-temperature and wear resistance, and potential decreased weight
This paper presents a critical review on the machining of TiMMCs with focus on tool wear mechanisms, material removal and chip formation mechanisms, and machined surface quality for turning, milling, and grinding operations
Summary
Titanium and its alloys have been the subject of significant research interest in different fields. The difference in mechanical properties between the matrix (ductile) and the particle reinforcements (brittle, hard, and abrasive), and the high strength and low heat transfer of TiMMCs present challenges during machining [9]. The surface defects constitute crack initiation sites rendering the workpieces vulnerable to fatigue resistance [11,12], which is essential for use in high-performance applications of TiMMCs. The literature contains a substantial amount of information regarding the machining of metal matrix composites (MMCs). There has been many activities on machining TiMMCs. The present paper provides an overview of the latest advances in machining of TiMMCs. The present paper provides an overview of the latest advances in machining of TiMMCs It covers the operations of turning, milling, and grinding with focus on the effect of different cutting parameters, material removal mechanisms, tool wear, and the surface finish. Comparisons of the behavior during machining between MMCs and TiMMCs are presented and discussed throughout the paper
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