The root cause of nose and flank wear and their behavior in turning Ti-6Al-4V with carbides and PCD inserts

Trung Nguyen, Patrick Kwon, D. Kang, Tom Bieler

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

This paper addresses the root cause for flank and nose wear when machining Ti alloys. In machining ferrous metals, at least the cementite (Fe3C) phase is present as the abrasive contributing to the flank wear. However, most titanium alloys possesses no significant hard phase, which questions the root cause for those wear. In this study, a Ti-6Al-4V bar was turned under various conditions with few grades of uncoated carbide and PCD-insert type tools. The cutting tools were retrieved sporadically after stopping the tuning process in order to examine the wear patterns and their evolution on the tools. The nose and flank wear patterns on the tool inserts were investigated with a confocal microscope. The microstructure of the bar was characterized using Orientation Image Microscope with Electron-Backscattered Diffraction Scan (EBDS). Two distinct types of damages were identified, (a) Micro-fracture at the cutting edge and (b) Scoring markings. Based on the microstructure and the tool wear patterns, this paper claims that both types of damages were caused primarily by the hard orientation of the alpha (α or Hexagonal Closed Packed) crystalline phases and secondarily by the adhesion layer detaching parts of the tool material from the nose and flank surfaces.

LanguageEnglish (US)
Title of host publicationASME 2014 International Manufacturing Science and Engineering Conference, MSEC 2014 Collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference
PublisherWeb Portal ASME (American Society of Mechanical Engineers)
Volume2
ISBN (Print)9780791845813
DOIs
StatePublished - 2014
EventASME 2014 International Manufacturing Science and Engineering Conference, MSEC 2014 Collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference - Detroit, United States
Duration: Jun 9 2014Jun 13 2014

Other

OtherASME 2014 International Manufacturing Science and Engineering Conference, MSEC 2014 Collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference
CountryUnited States
CityDetroit
Period6/9/146/13/14

Profile

Carbides
Wear of materials
Machining
Microscopes
Microstructure
Cutting tools
Titanium alloys
Abrasives
Electron diffraction
Adhesion
Tuning
Crystalline materials
Metals

Keywords

  • Abrasion
  • Carbide
  • Hard inclusion
  • Polycrystalline diamond (PCD)
  • Ti alloys
  • Ti-6Al-4V
  • Tool wear
  • Turning

ASJC Scopus subject areas

  • Industrial and Manufacturing Engineering

Cite this

Nguyen, T., Kwon, P., Kang, D., & Bieler, T. (2014). The root cause of nose and flank wear and their behavior in turning Ti-6Al-4V with carbides and PCD inserts. In ASME 2014 International Manufacturing Science and Engineering Conference, MSEC 2014 Collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference (Vol. 2). [V002T02A047] Web Portal ASME (American Society of Mechanical Engineers). DOI: 10.1115/MSEC2014-4116

The root cause of nose and flank wear and their behavior in turning Ti-6Al-4V with carbides and PCD inserts. / Nguyen, Trung; Kwon, Patrick; Kang, D.; Bieler, Tom.

ASME 2014 International Manufacturing Science and Engineering Conference, MSEC 2014 Collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference. Vol. 2 Web Portal ASME (American Society of Mechanical Engineers), 2014. V002T02A047.

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Nguyen, T, Kwon, P, Kang, D & Bieler, T 2014, The root cause of nose and flank wear and their behavior in turning Ti-6Al-4V with carbides and PCD inserts. in ASME 2014 International Manufacturing Science and Engineering Conference, MSEC 2014 Collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference. vol. 2, V002T02A047, Web Portal ASME (American Society of Mechanical Engineers), ASME 2014 International Manufacturing Science and Engineering Conference, MSEC 2014 Collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference, Detroit, United States, 6/9/14. DOI: 10.1115/MSEC2014-4116
Nguyen T, Kwon P, Kang D, Bieler T. The root cause of nose and flank wear and their behavior in turning Ti-6Al-4V with carbides and PCD inserts. In ASME 2014 International Manufacturing Science and Engineering Conference, MSEC 2014 Collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference. Vol. 2. Web Portal ASME (American Society of Mechanical Engineers). 2014. V002T02A047. Available from, DOI: 10.1115/MSEC2014-4116
Nguyen, Trung ; Kwon, Patrick ; Kang, D. ; Bieler, Tom. / The root cause of nose and flank wear and their behavior in turning Ti-6Al-4V with carbides and PCD inserts. ASME 2014 International Manufacturing Science and Engineering Conference, MSEC 2014 Collocated with the JSME 2014 International Conference on Materials and Processing and the 42nd North American Manufacturing Research Conference. Vol. 2 Web Portal ASME (American Society of Mechanical Engineers), 2014.
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AB - This paper addresses the root cause for flank and nose wear when machining Ti alloys. In machining ferrous metals, at least the cementite (Fe3C) phase is present as the abrasive contributing to the flank wear. However, most titanium alloys possesses no significant hard phase, which questions the root cause for those wear. In this study, a Ti-6Al-4V bar was turned under various conditions with few grades of uncoated carbide and PCD-insert type tools. The cutting tools were retrieved sporadically after stopping the tuning process in order to examine the wear patterns and their evolution on the tools. The nose and flank wear patterns on the tool inserts were investigated with a confocal microscope. The microstructure of the bar was characterized using Orientation Image Microscope with Electron-Backscattered Diffraction Scan (EBDS). Two distinct types of damages were identified, (a) Micro-fracture at the cutting edge and (b) Scoring markings. Based on the microstructure and the tool wear patterns, this paper claims that both types of damages were caused primarily by the hard orientation of the alpha (α or Hexagonal Closed Packed) crystalline phases and secondarily by the adhesion layer detaching parts of the tool material from the nose and flank surfaces.

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KW - Tool wear

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