Abstract
Ti-6Al-4V powder metallurgy materials with different densities were prepared by hot isostatic pressing technology. Shear band formation and wear mechanisms of the powder metallurgy materials were studied. The wear mechanisms of the powder metallurgy material were revealed that the micro-void torn and accumulated built-up edge in sticking friction and sticking zones, respectively. The wear mechanism of tool rake face was varied when the material density deceased. The shear plane shifted to the residual micro-void, which made a difference on fluctuation of cutting force and caused the appearance of severe micro-fluctuation. The micro-fluctuation of cutting force was weakened with decreasing the material density. Therefore, occasional random shear model of the powder metallurgy material was verified, and the progressions of chip morphology characteristic parameters with material density were studied, the micro-void on improved shear stress concentration. It could be concluded that the shear band mechanism of serrated chip in machining of titanium alloy was a catastrophic shear.
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