Documente Academic
Documente Profesional
Documente Cultură
a r t i c l e
i n f o
Article history:
Received 21 April 2008
Received in revised form
13 September 2008
Accepted 18 September 2008
Keywords:
Titanium Ti6Al4V
Surface integrity
Surface roughness
Residual stress
Milling
a b s t r a c t
End milling titanium Ti6Al4V has wide applications in aerospace, biomedical, and chemical industries.
However, milling induced surface integrity has received little attention. In this study, a series of end
milling experiments were conducted to comprehensively characterize surface integrity at various milling
conditions. The experimental results have shown that the milled surface shows the anisotropic nature
with the range of surface roughness values from 0.6 to 1.0 m. Surface roughness value increases with
feed and radial depth-of-cut (DoC), but has much less variation in the cutting speed range. Compressive
residual normal stress occurs in both cutting and feed directions, while the inuences of cutting speed and
feed on residual stress trend are quite different. The microstructure analysis shows that phase becomes
much smaller and severely deformed in the near surface with the cutting speed, but phase transformation
was absent for the milling conditions. The milled surface microhardness is about 7090% higher than the
bulk material in the subsurface.
2008 Elsevier B.V. All rights reserved.
1. Introduction
Corresponding author. Tel.: +1 205 348 2615; fax: +1 205 348 6419.
E-mail address: yguo@eng.ua.edu (Y.B. Guo).
0924-0136/$ see front matter 2008 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2008.09.022
J. Sun, Y.B. Guo / Journal of Materials Processing Technology 209 (2009) 40364042
4037
Table 2
Residual stress measurement parameters.
Table 1
Milling conditions.
Experiment
No.
Cutting speed
V (m/min)
Feed f
(mm/tooth)
Radial DoC ae
(mm)
Axial DoC ap
(mm)
1
2
3
4
5
6
7
8
9
10
11
12
13
50
65
80
95
110
65
65
65
65
80
80
80
80
0.08
0.08
0.08
0.08
0.08
0.06
0.1
0.12
0.14
0.08
0.08
0.08
0.08
4
4
4
4
4
4
4
4
4
2
3
5
6
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
1.5
Sin2
Measurement method
Radiation
Spot size (mm)
Voltage (kV)
Amperage (mA)
( )
2 ( )
Co K
0.8
40
35
10, 20, 30, 40, 0, 10, 20, 30, 40
47.45
Hughes et al. (2004) observed that phase deformation consisted of deformed boundaries and elongation grains in turning
Ti6Al4V. Che-Haron and Jawaid (2005) related the phase
deformed layer with tool wear conditions. The deformed layer was
very thin using a sharp tool while it is thick when the tool is nearly
worn out. Reissig et al. (2004) also observed subsurface deformation in drilling Ti6Al4V. Ezugwu et al. (2007) pointed out that in
ne cutting conditions, the shearing forces cannot cause severe
plastic deformation in the subsurface regardless of conventional or
high pressure cooling condition.
Besides phase deformation, microstructural changes such as the
absence of phase close to the hole surface have been shown in
drilling Ti6Al4V (Canteroa et al., 2005). The SEM-EDS analysis
showed that there exists an absence of phase close to the hole
surface. Similar results were also reported by Li et al. (2007). The
phase transformation from phase to phase was induced by high
temperatures resulted from the severe plastic deformations.
4038
J. Sun, Y.B. Guo / Journal of Materials Processing Technology 209 (2009) 40364042
carried out with water-soluble cutting uid. The detail milling conditions are listed in Table 1. Five levels of cutting speed, feed, and
radial DoC were selected, while the axial DoC was kept a constant
value. A sharp cutting edge was used at milling condition to ensure
measurement repeatability and fair comparison.
Fig. 3. The effect of radial DoC (ae ) on surface topography (V, 80 m/min; f, 0.08 mm/tooth; ap = 1.5 mm).
J. Sun, Y.B. Guo / Journal of Materials Processing Technology 209 (2009) 40364042
4039
Fig. 4. The inuence of tool path on surface pattern (V, 80 m/min; f, 0.08 mm/tooth; ae = 3 mm; ap = 1.5 mm). (a) Cutting speed effect (f, 0.08 mm/tooth; ae = 4 mm; ap = 1.5 mm).
(b) Feed effect (V, 65 m/min; ae = 4 mm; ap = 1.5 mm). (c) Radial DoC effect (V, 80 m/min; f, 0.08 mm/tooth; ap = 1.5 mm).
4040
J. Sun, Y.B. Guo / Journal of Materials Processing Technology 209 (2009) 40364042
Fig. 6. The inuence of milling parameters on surface residual stress (V, 65 m/min;
ae = 4 mm; ap = 1.5 mm).
Fig. 5. The inuence of milling parameters on surface roughness. (a) Cutting speed
inuence (f, 0.08 mm/tooth; ae = 4 mm, ap = 1.5 mm). (b) Feed inuence.
J. Sun, Y.B. Guo / Journal of Materials Processing Technology 209 (2009) 40364042
4041
Fig. 7. Cross-section view of subsurface microstructure (f, 0.08 mm/tooth; ae = 4 mm; ap = 1.5 mm).
Fig. 8. Microhardness distribution and variation in the subsurface (f, 0.08 mm/tooth;
ae = 4 mm, ap = 1.5 mm).
4042
J. Sun, Y.B. Guo / Journal of Materials Processing Technology 209 (2009) 40364042
Acknowledgements
The authors would like to thank the assistance of Drs. Andrew
Warren, Mark Barkey and Mark Weaver for preparing samples and
surface integrity characterization.
References
Amin, N.A.K.M., Ismail, A.F., Khairusshima, N.M.K., 2007. Effectiveness of uncoated
WCCo and PCD inserts in end milling of titanium alloyTi6Al4V. J. Mater.
Proc. Technol. 192/193, 147158.
Canteroa, J.L., Tardiob, M.M., Cantelia, J.A., Marcosc, M., Miguelez, M.H., 2005. Dry
drilling of alloy Ti6Al4V. Int. J. Machine Tools Manuf. 45, 12461255.
Che-Haron, C.H., Jawaid, A., 2005. The effect of machining on surface integrity of
titanium alloy Ti6%Al4%V. J. Mater. Proc. Technol. 166, 188192.
Copper, D., 2006. Machining capacity, expertise must grow. SME/Aerospace Defense
Manuf. Manuf. Eng., 6365.
Ezugwu, E.O., 2005. Key improvements in the machining of difcult-to-cut aerospace
superalloys. Int. J. Machine Tools Manuf. 45, 13531367.
Ezugwu, E.O., Bonneya, J., Silvab, R.B.D., Cakir, O., 2007. Surface integrity of nished
turned Ti6Al4V alloy with PCD tools using conventional and high pressure
coolant supplies. Int. J. Machine Tools Manuf. 47, 884891.
Fitzpatrick, M.E., Fry, A.T., Holdway, P., Kandil, F.A., Shackleton, J., Suominen, L., 2002.
Determination of residual stresses by X-ray diffraction. Meas. Good Practice
Guide 52, 159.
Hauk, V., 1997. Structural and Residual Stress Analysis by Nondestructive Methods.
Elsevier Science, Danvers, MA.
Hong, H., Riga, A.T., Cahoon, J.M., 1993. Machinability of steels and titanium alloys
under lubrication. Wear 162, 3439.
Hughes, J.I., Sharman, A.R.C., Ridgway, K., 2004. The effect of tool edge preparation
on tool life and workpiece surface integrity. Proc. Inst. Mech. Eng., Part B: J. Eng.
Manuf. 218, 11131123.
Kahles, J.F., Field, M., Eylon, D., Froes, F.H., Metals, J., 1985. Mach. Titanium 37, 2735.
Li, R., Riester, L., Watkins, T.R., Blau, P.J., Shih, A.J., 2007. Metallurgical analysis and
nanoindentation characterization of Ti6Al4V workpiece and chips in highthroughput drilling. Mater. Sci. Eng. A 472, 115124.
Lopez de lacalle, L.N., Perez, J.I., Llorente, J., Sanchez, J.A., 2000. Advanced cutting
conditions for the milling of aeronautical alloys. J. Mater. Proc. Technol. 100,
111.
Norihiko, N., Akio, M., Suquru, M., 1983. Study on machining of titanium alloys. CIRP
Ann. 32, 6569.
Reissig, L., Volkl, R., Mills, M.J., Glatzel, U., 2004. Investigation of near surface structure in order to determine process-temperatures during different machining
processes of Ti6Al4V. Scr. Mater. 50, 121126.
Ribeiro, M.V., Moreira, M.R.V., Ferreira, J.R., 2003. Optimization of titanium alloy
(Ti6Al4V) machining. J. Mater. Proc. Technol. 143/144, 458463.
Snoha J., 1996. X-ray diffraction characterization of process-induced residual stress.
Army Research Laboratory ARL-TR-1204.
Su, Y., He, N., Li, L., Li, X.L., 2006. An experimental investigation of effects of cooling/lubrication conditions on tool wear in high-speed end milling of Ti6Al4V.
Wear 261, 760766.
Sun, J., Guo, Y.B., 2008. A new multi-view approach to characterize 3D chip morphology and properties in end milling titanium alloy Ti6Al4V. Int. J. Machine
Tools Manuf. 48, 14861494.
Warren, A.W., Guo, Y.B., 2006. On the clarication of surface hardening by hard
turning and grinding. Trans. NAMRI/SME 34, 309316.
Yang, X.P., Liu, C.R., Grandt, A.F., 2002. An experimental study on fatigue life variance, residual stress variance, and their correlation of face-turned and ground
Ti6Al4V samples. J. Manuf. Sci. Eng. 124, 809819.
Zlatin, N., Field, M., 1973. Procedures and precautions in machining titanium alloys.
Titanium Sci. Technol. 1, 489504.
Zoya, Z.A., Krishnamurthy, R., 2000. The performance of CBN tools in the machining
of titanium alloys. J. Mater. Proc. Technol. 100, 8086.