The Machinability of Ultrafine-grained Grade 2 Ti Processed by Equal Channel Angular Pressing

Journal of Materials Research and Technology

w w w. j m r t . c o m . b r

ORIGINAL ARTICLE

The Machinability of UltraÀne-grained Grade 2 Ti Processed by Equal Channel Angular Pressing Armando Ítalo Sette Antonialli1,*, Anibal de Andrade Mendes Filho1, Vitor Luiz Sordi2, Maurizio Ferrante2 Graduate Program on Materials Science & Engineering (PPG-CEM), Universidade Federal de São Carlos (UFSCar), São Carlos, Brazil. Department of Materials Engineering (DEMa), Universidade Federal de São Carlos (UFSCar), São Carlos, Brazil.

1 2

Manuscript received April 4, 2012; in revised form September 6, 2012.

All processes of severe plastic deformation (SPD) are known to improve the mechanical strength of metals and alloys through microstructural reÀnement. Although the literature contains a large number of investigations on the effect of Àne-grained microstructures on mechanical behaviour, data on the machinability is almost non-existent. This lack of information motivated the present work, in which the machinability of severely-deformed Grade 2 Ti is assessed in terms of cutting forces and the resulting product surface roughness. The SPD process here employed is Equal Channel Angular Pressing (ECAP), and the results are compared with those obtained on Ti and Ti-6% aluminum-4% vanadium (Ti6-4) alloy, both in the annealed condition. It was observed that the machining of ultraÀne-grained Ti in the as-deformed state, requires larger cutting forces than the necessary for the annealed material, whilst for the alloy, the forces are of the same order. Due to continuous chip generation taking place in commercially pure Ti but not in Ti6-4, the passive component of the cutting force and the average surface roughness of the Àne grained material are higher. Finally, whilst both annealed and Àne grained Ti wear the tool by an attrition mechanism, titanium alloy machining promotes only adhesion over the tool edge. KEY WORDS: Severe plastic deformation; Equal channel angular pressing; Titanium; Machinability. © 2012 Brazilian Metallurgical, Materials and Mining Association. Published by Elsevier Editora Ltda. All rights reserved.

1. Introduction The term machinability may be taken to imply that there is a property or quality of any given material which can be clearly deÀned and quantiÀed, thus indicating how easy (or difÀcult) that mechanical operation can be. In fact, that term is not unambiguous, but the machinability of a material can be assessed by employing criteria such as: (i) tool *Corresponding author. E-mail address: [email protected] (A.I. S. Antonialli)

life or limiting rate of metal removal; (ii) cutting forces or power consumption; and (iii) surface Ànish and chip morphology[1]. Machinability ratings for any given material can be experimentally determined using a given type of cutting tool under a constant set of cutting conditions[2]. On this respect, Yamane et al.[3] proposed a criteria known as “difÀcult-tocut rating” (DTCR), expressed by the area of a radar chart that contemplates hardness, mechanical strength, elongation, and thermal features of the material under consideration. These attributes maintain a close relationship with

© 2012 Brazilian Metallurgical, Materials and Mining Association. Published by Elsevier Editora Ltda. All rights reserved.

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The Machinability of UltraÀne-grained Grade 2 Ti Processed by Equal Channel Angular Pressing tool life, cutting forces and temperatures, surface Ànishing, and chip morphology. The smaller the chart area, the better the material machinability. Experimental data are referred to the DTCR of AISI 1045 steel, which is arbitrarily set as equal to the unity. The DTCR radar chart concept is illustrated in Fig. 1, where Vickers hardness (HV) and percent elongation (%EL) are plotted on the north-south axis. Ultimate tensile strength – TS (MPa) – and (k.Ŭ.c)-1/2 are plotted on the eastwest axis. The last parameter, where k (W/m.K) is the material thermal conductivity, Ŭ (g/cm3) density and cp (J/kg.K) the speciÀc heat at constant pressure, is proportional to the cutting temperature. Machinability can be compared by different ways and is determined by several diferent types of tests. For example, besides the main cutting force, the cutting force test measures the passive (Fp) and the feed components (Ff) necessary to machine the material under standardized conditions, see Fig. 2 for the identiÀcation of said forces[4]. The lower the force, the more machinable is the material. Another currently used machinability criterion is the surface quality of the machined part[2].

Cutting temperature

Cutting forces (HV)

(k.ȡ.c)-1/2

AISI 1045

TS (MPa)

%EL Chip breakability Fig. 1 Radar chart depicting difÀcult-to-cut rating (DTCR) conception[3]

Rake face 3

4

1

2

End clearance face

Flank face Nose radius

1 - Flank wear 2 - Nose wear

3 - Notch wear 4 - Crater wear

Fig. 3 Typical tool wear features found on titanium machining[6]

Ti and its alloys are among the most difÀcult materials to machine, mainly because of the metal reactivity at medium to high temperatures, from which a tendency to weld to the tool while machining leads to chipping and premature tool failure. Additionally, its low heat conductivity increases the temperature at the tool-workpiece interface. Finally, the low elastic modulus of Ti allows relatively large deÁections of the workpiece[5], which affect adversely the tool life. Rapid Áank wear, crater wear, nose wear and notching defects, here summarized in Fig. 3[6], are commonly found on the machining of Ti and its alloys. It is well known that severe plastic deformation (SPD)processed materials are characterized by ultraÀne grains, leading to signiÀcantly enhanced mechanical properties, including high cycle fatigue strength[7]; thus, such materials are viewed as “advanced structural and functional materials of the next generation of metals and alloys”[8]. Among the available SDP techniques, Equal Channel Angular Pressing (ECAP) has attracted a great deal of attention by its effectivity in producing bulk ultraÀne-grained billets and plates[9] – having submicron or even nanosized grains – which are large enough for commercial applications[10]. In general investigation on SPD processing of Ti or any other material deals with grain size reduction mechanisms, and related changes of mechanical behavior. For instance, Stolyarov et al.[11] studied the inÁuence of deformation by rolling applied to previously ECAP processed Grade 2 Ti on the microstructure, tensile properties, and microstructural stability; Sabirov et al.[12] investigated the fracture behavior, whilst Zhao et al.[13] evaluated the effect of multiple ECAP passes on the mechanical strength. However, there is a lack of studies directed to what may be called engineering properties: machinability, workability, and corrosion behavior. The aim of this paper is to evaluate how ECAP processing affects the machinability of Grade 2 Ti, an important piece of knowledge in the context of the evolution of SPD technology from laboratory to commercial scale.

2. Experimental Procedures

Fig. 2 Components measured in a cutting force test[4]

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Three sets of samples, each one with three workpieces, were submitted to cutting force and surface Ànish tests in order to assess the inÁuence of SPD over machinability: (i)

Antonialli et al.

150 Grade 2 Ti in the annealed condition (0X – coarse grained); (ii) same material after four ECAP passes performed at 300°C (4XH – ultraÀne grained)[14]; and (iii) annealed Ti-6% aluminum-4% vanadium (Ti6-4) (#5 – coarse grained). As for DTCR[3], Fig. 4 shows that from literature data the parameter resulted values equal to 3.14 for the alloy[15] and 1.70 and 1.90 for samples 0X and 4XH[14], respectively. Therefore, it is expected that after SPD machinability will be reduced, although by a small extent. Machining tests were held on a Romi S20 conventional turning machine, using a 95° entering angle and î6° rake angle tool holder (manufacturer's code DCLNR 2525 M 12) and ISO HC S05-S15 grade CVD-coated (TiN+Al2O3+TiCN) carbide inserts having 1.2 mm nose radius (manufacturer's code CNMG 12 04 12-QM S05F). Following the manufacturer's instructions[16], cutting speed, feed, and depth of cut were kept, respectively equal to, 63 m/min, 0.042 mm/rev, and 0.5 mm as shown in Table 1. No cutting Áuid was employed. All measurements of cutting forces were made setting the tool on a Kistler 9257B multicomponent dynamometer connected to a Kistler 5019B charge ampliÀer and a NI PCI6025E multifunctional data acquisition board. The NI LabVIEW 8.5 software was used to process signals received by the computer (Fig. 5), where Fp, Ff, and Fc are, respectively, the passive, the feed, and the main cutting force components measured over the tool. Acquisition rate was Àxed as 2 kHz, and a 1 kHz low pass Àlter was applied. The passive component of cutting force, commonly the smallest among all components, provides no load over machining power, as it is orthogonal to the work plane. Feed

HV

TS

(k.ȡ.c)-1/2

charge amplifier dynamometer acquisition board

tool PC Ff

Fp Fc sample

Fig. 5 Setup for cutting forces measurements

power is very small when compared to cutting power, as both cutting force feed component and feed rate are small. On the other hand, the main cutting force, which is the largest of all, may be calculated by Eq. (1)[17], where ks is the speciÀc cutting pressure (usually available in tool manufacturers catalogues for several materials and Àxed tool geometry), while feed (f = 0.042 mm/rev) and depth of cut (ap = 0.5 mm) are the chosen cutting parameters[17]. Therefore, knowing the main cutting force it is possible to determine the speciÀc cutting pressure for a given material in any tooling setup.

Fc αks ȋap Ǥ f ȌαͲǤͲʹͳs

(1)

After the machining tests, each sample was subjected to surface roughness measurement using a Time TR200 portable rugosimeter. Arithmetical mean roughness (Ra) was analyzed using Gauss Àlter and keeping the evaluation length equal to Àve times the cut-off, chosen according to ISO 4287[18]. Additionally, both Áank and rake faces of the worn tool edges were examined in a Philips XL30 Field-Emission Environmental Scanning Electron Microscope (ESEM-FEG) Àtted with Energy-Dispersive Spectroscopy (EDS) attachments, in order to detect differences regarding the main wear mechanisms acting in each test.

3. Results and Discussion Fig. 6 shows data on cutting force obtained on Grade 2 Ti, samples 0X, 4XH and on the Ti6-4 alloy, sample #5. It can be seen that ECAP processing of the ultraÀne-grained Ti al-

%EL Fig. 4 DifÀcult-to-cut rating (DTCR) for 0X, 4XH and #5 titanium

Table 1 Tooling and cutting parameters employed in the machining tests Holder

DCLNR 2525M 12

Insert

CNMG 12 04 12-QM S05F

Cutting speed

63 m/min

Tooling

Parameters

Feed

0.042 mm/rev

Depth of cut

0.5 mm

Fig. 6 Cutting forces in 0X, 4XH, and #5 turning

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The Machinability of UltraÀne-grained Grade 2 Ti Processed by Equal Channel Angular Pressing most doubled the main cutting force (Fc) required for the tests, reaching values close to that measured on alloy. Also, the feed force (Ff) required for the 4XH sample was three times larger than the value measured on sample 0X and of the same order than that of sample #5. Finally, the passive component of the cutting force (Fp) was even more affected by ECAP: it was four times larger than the force measured on sample 0X and twice as much as the value measured on the #5 sample. The Student t test, which is appropriated to compare two treatment means, statistically conÀrms the equality between Ff and Fc components for 4XH and #5 and the superiority of the former sample in terms of Fp (Fig. 7), where t0 is the test statistic[19]. From the above results it is clear that SPD decreases Ti machinability, as all cutting force components increase. However, this is in contrast with the radar chart DCTR values, which anticipate a relative equality between the coarse and the ultraÀne-grained sample (Fig. 4). In fact, the machinability of the ECAP-deformed Ti is even slightly lower than that of the alloy, again in desagreement with the radar chart data. The large value of the cutting force passive component of ultraÀne-grained Ti may be ascribed to the type of chip generated, a feature which depends on the material ductility. The more ductile Ti was observed to produce a continuous chip – a condition leading to huge shear stress over the rake surface of the tool – while the discontinuous chip produced by #5 alloy sample meant that such effect was absent. The SPD effect over the main cutting force reÁects on the speciÀc cutting pressure (ks), which is calculated by

Eq. (1) and plotted in Fig. 8. Regardless of its dependence on cutting thickness, this parameter may be used to estimate the cutting forces when employing other machining parameters, since the same tool geometry (95° entering and î6° rake angle) is maintained. It must be pointed out that ks, when calculated for the coarse-grained Ti and the annealed Ti6-4, exhibits a very different value from that given in the tools suplier data[16], which is known to assume a positive tooling setup. Data on mean surface roughness (Ra) of all specimens after the turning tests are shown in Fig. 9. For both annealed and ECAPed titanium, roughness data is highly scattered, with a Ra of about 2.00 —m, whilst for the alloy Ra is 1.00 —m and was obtained from a collection of less scattered data. The difference of surface quality is quite pronounced, corresponding respectively to Grades N8 and N7, as deÀned by the ISO 1302 Standard[20]. This difference on surface roughness may be attributed to different chip types obtained from the different materials during the turning tests: coarse-grained or ultraÀnegrained Ti produced reasonably ductile continuous chips, that may scratch newly machined surface, thus causing damage to the samples surface, whilst the alloy produced a discontinuous type. Fig. 10 shows SEM micrographs of the worn tool Áank face after machining tests of annealed Ti (0X). Strong adhesion of workpiece material (rough Ti layers) is aparent over the exposed tool substrate material – W and Co on

Fig. 9 Mean surface roughness for 0X, 4XH, and #5

Fig. 7 Student t test for cutting force components on 4XH and #5 machining

Fig. 8 SpeciÀc cutting pressure for 0X, 4XH, and #5

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Fig. 10 Tool Áank face after 0X samples machining

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152 lighter areas. This is a typical indication that attrition is the main acting wear mechanism. When turning at relatively low speeds, the workpiece material usually builds on the cutting edge and tool fragments of microscopic size that are periodically torn from it, leading to large tool wear[1]. Sequentially (Fig. 11), chip traces of Ti are often found on the tool rake surface, as the workpiece material is known to be very ductile. SEM photographs taken on Áank and rake faces of the tool used on 4XH turning experiments can be seen in Figs. 12 and 13, respectively. They show some typical attrition mechanism features, that is, tool material (W, Co) exposure and workpiece material (Ti) stuck on it, besides chip adherence. From Figs. 10 and 11, the same conclusions can be extended to coarse-grained annealed Ti.

Finally, Fig. 14 shows the Ti alloy worn tool Áank face after the turning test. Adhesion of the workpiece material (Ti, Al, V) is apparent but there was no exposure of tool substrate, as the tool coating elements (Ti, Al, and O) can still be detected by EDS on the tool surface. This indicates that the tool wear mechanism acting on the alloy machining differs from that acting on both annealed and ECAP-deformed Ti. Klocke[4] deÀnes adhesion as the formation of atomic bonds between tool and workpiece. It is considered as a consequence of diffusion and mechanical snagging, which is different from attrition mechanism. As the hardness is higher than that of the metal, the tool-workpiece interface temperature is also higher, a condition which stimulates atomic diffusion between tool coating and the workpiece, both constituted by the same material. Differently from what was observed on 0X and 4XH samples, the alloy tool rake surface shows almost no chip trail (Fig. 15), since discontinuous chips are formed and as a consequence, there were no scratches over the tool surface. Said micrograph reinforces earlier assumptions put forward when discussing the results concerning the passive component of the cutting force and the corresponding surface roughness. That is, continuous chips generated when machining the 4XH sample100 are responsible for the higher Fp and Ra than those measured on sample #5.

Fig. 11 Tool rake face after 0X samples machining

Fig. 14 Tool Áank face after #5 samples machining

Fig. 12 Tool Áank face after 4XH samples machining

Fig. 13 Tool rake face after 4XH samples machining

Fig. 15 Tool rake face after #5 samples machining

J. Mater. Res. Technol. 2012; 1(3):148-153

The Machinability of UltraÀne-grained Grade 2 Ti Processed by Equal Channel Angular Pressing

4. Conclusions ECAP processing of Grade 2 Ti sharply decreases machinability; indeed, the main cutting force required on turning these specimens reach the same level measured on the Ti6-4 alloy, and is much larger than that required by the coarse-grained Ti. Aditionally, the speciÀc cutting pressure of SPD titanium and of the alloy are of the same order of magnitude. Because of the continuous chip generated when machining the 4XH sample, the passive component of the cutting force is also higher than that measured on Ti6-4 alloy. By the same reason, the quality of the turned surfaces of both annealed and ECAP-deformed Ti was lower than that exhibited by the Ti6-4 material turned surface. Attrition was found to be the main wear mechanism acting on Grade 2 Ti, regardless of its condition, since a strong adhesion of workpiece material followed by tool particles pull out was observed. On the other hand, adhesion without substrate material exposure took place when machining the Ti alloy.

Acknowledgements The authors would like to thank all staff from Unicamp Machining Materials Laboratory for the support during the tests, and IFSP - São Carlos for use of their equipment. Thanks also to Sandvik Coromant for providing the cutting tools, Capes for granting a PhD scholarship and Fapesp for Ànancial support.

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