Table Of Content

MachinabilityofAdvancedMaterials Machinability of Advanced Materials Edited by J. Paulo Davim Firstpublished2014inGreatBritainandtheUnitedStatesbyISTELtdandJohnWiley&Sons,Inc. Apart from any fair dealing for the purposes of research or private study, or criticism or review, as permittedundertheCopyright,DesignsandPatentsAct1988,thispublicationmayonlybereproduced, storedortransmitted,inanyformorbyanymeans,withthepriorpermissioninwritingofthepublishers, or in the case of reprographic reproduction in accordance with the terms and licenses issued by the CLA. Enquiries concerning reproduction outside these terms should be sent to the publishers at the undermentionedaddress: ISTELtd JohnWiley&Sons,Inc. 27-37StGeorge’sRoad 111RiverStreet LondonSW194EU Hoboken,NJ07030 UK USA www.iste.co.uk www.wiley.com ©ISTELtd2014 TherightsofJ.PauloDavimtobe identifiedastheauthorofthisworkhavebeenassertedbyhimin accordancewiththeCopyright,DesignsandPatentsAct1988. LibraryofCongressControlNumber: 2013955373 BritishLibraryCataloguing-in-PublicationData ACIPrecordforthisbookisavailablefromtheBritishLibrary ISBN978-1-84821-396-8 PrintedandboundinGreatBritainbyCPIGroup(UK)Ltd.,Croydon,SurreyCR04YY Table of Contents Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix Chapter1.Machinability:ExistingandAdvancedConcepts . . . . . . . . . 1 ViktorP.ASTAKHOV 1.1.Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.2.Traditionalconceptsofmachinabilityandmethodsforitsassessment. 3 1.2.1.Commonperceptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.2.2.Non-standardizedtestsformachinabilityassessment. . . . . . . . . 5 1.2.3.Standardtests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.2.4.Assessmentsusedinmachiningpractice . . . . . . . . . . . . . . . . 15 1.2.5.Themeritoftheknownconceptsofmachinability . . . . . . . . . . 16 1.3.Knowledge-basedfoundationsofmachinability . . . . . . . . . . . . . . 16 1.3.1.Practicalneed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 1.3.2.Abilityoftheprevailingmetalcuttingtheory . . . . . . . . . . . . . 17 1.3.3.Notionoftwokindsofmachinability . . . . . . . . . . . . . . . . . . 18 1.3.4.Machinabilityoftheworkmaterial . . . . . . . . . . . . . . . . . . . 19 1.3.5.Processmachinability . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 1.3.6.Improvementtheprocessmachinability . . . . . . . . . . . . . . . . 35 1.4.Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Chapter2.MillingBurrFormationandAvoidance. . . . . . . . . . . . . . . 57 SeyedA.NIKNAM,WaleryWYGOWSKI,MarekBALAZINKSIand VictorSONGMENE 2.1.Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 2.1.1.Definitionandclassificationofburrs . . . . . . . . . . . . . . . . . . 58 2.1.2.Factorsgoverningmillingburrformation . . . . . . . . . . . . . . . 62 2.1.3.Burrformationmodelingandcontrol . . . . . . . . . . . . . . . . . . 63 2.1.4.Burravoidanceandremoval(deburring) . . . . . . . . . . . . . . . . 64 vi MachinabilityofAdvancedMaterials 2.2.Casestudy1:burrformationduringslotmillingofaluminumalloys. . 69 2.2.1.Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 2.3.Casestudy2:burrlimitationandtoolpathplanningstrategies– applicationtotheslotmillingofAM6414steel . . . . . . . . . . . . . . . . . 77 2.3.1.Burrsizeestimationduringslotmilling(approachesCH1,CH2 andCH3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 2.3.2.Conclusiononcasestudy2burrlimitationduringslotting . . . . 86 2.4.Generalconcludingremarks. . . . . . . . . . . . . . . . . . . . . . . . . . 86 2.5.Acknowledgments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 2.6.Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Chapter3.MachinabilityofTitaniumandItsAlloys. . . . . . . . . . . . . . 95 AliHOSSEINI,HossamA.KISHAWYandHusseinM.HUSSEIN 3.1.Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 3.2.Titanium:abriefoverview. . . . . . . . . . . . . . . . . . . . . . . . . . . 97 3.3.Titaniumalloys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 3.4.Challengestowardmachiningtitanium . . . . . . . . . . . . . . . . . . . 99 3.4.1.Lowmodulusofelasticity. . . . . . . . . . . . . . . . . . . . . . . . . 99 3.4.2.Poorthermalconductivity. . . . . . . . . . . . . . . . . . . . . . . . . 99 3.4.3.Chemicalreactivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 3.4.4.Hardeningcharacteristics . . . . . . . . . . . . . . . . . . . . . . . . . 101 3.5.Mechanicsofchipformation . . . . . . . . . . . . . . . . . . . . . . . . . 101 3.6.Cuttingforcesandpowerconsumption . . . . . . . . . . . . . . . . . . . 104 3.7.Cuttingtoolsandwearphenomenon . . . . . . . . . . . . . . . . . . . . . 105 3.7.1.High-speedsteeltools . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 3.7.2.Carbidetools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 3.7.3.Ceramictools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 3.7.4.Cubicboronnitride(CBN)tools. . . . . . . . . . . . . . . . . . . . . 112 3.8.Applicationofcoolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 3.9.Surfaceintegrity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 3.10.Concludingremarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 3.11.Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Chapter4.EffectsofAlloyingElementsontheMachinabilityof Near-EutecticAl-SiCastingAlloys . . . . . . . . . . . . . . . . . . . . . . . . . 119 YasserZEDAN,SalehA.ALKAHTANIandFawzyH.SAMUEL 4.1.Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 4.2.Alloypreparationandcastingprocedures. . . . . . . . . . . . . . . . . . 122 4.2.1.Metallography-microstructuralexamination. . . . . . . . . . . . . . 123 4.2.2.Mechanicaltests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 4.2.3.Machiningprocedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 4.2.4.Totaldrillingforce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 TableofContents vii 4.2.5.Toollifecriteria. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 4.3.Results. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 4.3.1.Microstructures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 4.3.2.Hardnessandtensileproperties. . . . . . . . . . . . . . . . . . . . . . 129 4.3.3.Machiningbehavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 4.4.Discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136 4.5.Conclusions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 4.6.Acknowledgments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 4.7.Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Chapter5.TheMachinabilityofHardMaterials–AReview. . . . . . . . . 145 PauloCAMPOS, J.PauloDAVIM,J.RobertoFERREIRA,A.PauloPAIVA andP.PauloBALESTRASSI 5.1.Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 5.1.1.Definitionofhardmachining. . . . . . . . . . . . . . . . . . . . . . . 145 5.1.2.Applicationofhardmachiningprocesses. . . . . . . . . . . . . . . . 146 5.2.Cuttingtools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 5.2.1.Ceramics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 5.2.2.Cubicboronnitride(CBN) . . . . . . . . . . . . . . . . . . . . . . . . 149 5.3.Wipertechnology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 5.4.Machinability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 5.4.1.Cuttingparameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 5.4.2.Cuttingforces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 5.4.3.Chipformation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156 5.4.4.Cuttingtemperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 5.5.Surfaceintegrityinhardmachiningprocesses . . . . . . . . . . . . . . . 159 5.5.1.Surfaceintegrity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 5.5.2.Surfaceroughness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 5.5.3.Residualstresses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 5.5.4.White-layereffect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 5.6.Optimizationofhardmachiningprocesses . . . . . . . . . . . . . . . . . 163 5.7.Synthesis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 5.8.Acknowledgments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 5.9.Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166 Chapter6.AnInvestigationofDuctileRegimeMachiningof SiliconNitrideCeramics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 VijayanKRISHNARAJandS.SenthilKUMAR 6.1.Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 6.2.Ceramicmachining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 6.2.1.Machiningforces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 6.2.2.Surfacequality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 viii MachinabilityofAdvancedMaterials 6.2.3.Machiningmodel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178 6.3.Ductileregimemachining . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 6.3.1.Factorscontributingtotheductile-regimemachiningofceramics. 182 6.4.Developmentsinsimulationsofceramicmachining. . . . . . . . . . . . 185 6.4.1.Materialmodelforsimulations. . . . . . . . . . . . . . . . . . . . . . 186 6.4.2.Elasticandplasticbehavior. . . . . . . . . . . . . . . . . . . . . . . . 188 6.4.3.Heattransferandthermalsoftening . . . . . . . . . . . . . . . . . . . 188 6.4.4.Strainratesensitivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 6.4.5.Determinationofinitialyieldstress . . . . . . . . . . . . . . . . . . . 191 6.4.6.Materialmodelvalidation. . . . . . . . . . . . . . . . . . . . . . . . . 192 6.4.7.SimulationmodelofAdvantEdge®. . . . . . . . . . . . . . . . . . . 193 6.4.8.Workmaterialproperties . . . . . . . . . . . . . . . . . . . . . . . . . 195 6.4.9.Wearmodel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 6.4.10.Processparameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 6.4.11.Convergence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 6.5.Designofexperiments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 6.5.1.Tabulationofresults . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 6.5.2.Resultsanddiscussion. . . . . . . . . . . . . . . . . . . . . . . . . . . 201 6.6.Effectofthedepthofcut. . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 6.7.Effectofthefeedrate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205 6.7.1.Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 6.8.Materialsandmeans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 6.8.1.Hardnesstest. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206 6.8.2.FracturetoughnessK –microindentationtest. . . . . . . . . . . . 208 IC 6.8.3.Elasticmodulus–semi-empiricalrelation . . . . . . . . . . . . . . . 209 6.8.4.Materialpreparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 6.8.5.Fixturebase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 6.8.6.Gluingtheceramictothefixturebase. . . . . . . . . . . . . . . . . . 211 6.8.7.PCDendmilltool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211 6.9.Experimentalset-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 6.9.1.Resultsanddiscussion. . . . . . . . . . . . . . . . . . . . . . . . . . . 214 6.9.2.Effectofthedepthofcut . . . . . . . . . . . . . . . . . . . . . . . . . 216 6.9.3.Effectofthefeedrate . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 6.9.4.Surfaceroughness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 6.9.5.Analysisofvariance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 6.9.6.Resultantforce . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 6.9.7.Surfaceroughness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221 6.9.8.Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 6.10.Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223 ListofAuthors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

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