Abstract
Scanning electron microscopy (SEM) has been used to identify and analyse the secondary adhesion effect precursors formed during the dry drilling processes of Ti-6Al-4V alloy over the rake face and flute of the drilling tools. Subsequent analysis with energy dispersive spectroscopy (EDS) was enabled to distinguish its compositional characteristics. Thus, according to the EDS obtained data, a stratified multi built-up layer (MBUL) composed by TiOxis formed over the rake face of the tool. Furthermore, this multi-layer adhered allows initially the built-up edge (BUE) development close to the edge of the tool by a mechanical adhesion mechanism. In a second step, it is responsible for the formation of a thicker secondary BUL which avoids the chip flow, and it provokes the tool collapse. These mechanisms are different from those observed in the dry machining of other alloys such as steels, nickel-based alloys, or aluminium alloys.
Highlights
Nowadays, light alloys, mainly aluminium and titaniumbased alloys, are wide and commonly applied for building structural components of aircrafts and aerospace vehicles, due to the excellent relationship weight/cost/mechanical properties [1,2,3,4,5,6,7]
Secondary adhesion tool wear is mainly related to the built-up edge (BUE) and built-up layer (BUL) formation and its later elimination by the chip
The analysis on the results reported in research works focused on the origin of BUL and BUE has revealed that BUL and BUE formation mechanisms depend strongly of the workpiece material
Summary
Light alloys, mainly aluminium and titaniumbased alloys, are wide and commonly applied for building structural components of aircrafts and aerospace vehicles, due to the excellent relationship weight/cost/mechanical properties [1,2,3,4,5,6,7]. Environmental laws recommend avoiding to cut fluid because most of them have a nondesirable environmental impact and/or can cause damage to human health [12, 13] These fluids can increase tool life, the current dominant trend in machining processes consists in avoiding their use [12, 14, 15]. Cutting tool wear study is one of the most relevant analysis that can be made in order to characterise tool life and, as consequence of this, to predefine cutting conditions for obtaining a high degree of optimisation in a cutting process. A review of the main secondary adhesion wear mechanism reported by different researchers has been achieved.
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