Understanding the surface generation mechanism during microscratching of Ti-6Al-4V

Journal article

Pratap, A., Divse, V., Goel, S. and Joshi, S.S (2022). Understanding the surface generation mechanism during microscratching of Ti-6Al-4V. Journal of Manufacturing Processes. 82, pp. 543-558. https://doi.org/10.1016/j.jmapro.2022.08.014
AuthorsPratap, A., Divse, V., Goel, S. and Joshi, S.S
Abstract

A lot of grinding research in the past has been emulated using single grit scratching. This limits studying surface generation mechanism due to overlapping scratches inherent to the grinding process. It not only affects the surface generation mechanism, but also limits studying elastic
recovery which has a significant effect on the final form and topography including the roughness generated after grinding. Taking Ti-6Al-4V as a testbed, this investigation was directed on comparing single scratches with adjacent scratches, which are often referred to as double scratches in literature. During the experiments, the effect of scratch speed, infeed angle and the scratch separation distance on the material removal mechanism in terms of cutting forces, material pile-up area ratio (PA), groove depth, material removal area (MRA) and subsurface deformation were investigated. It was found that the scratch speed significantly affects the pile-up and groove depth because of the phenomenon like stress build up and elastic recovery. A complementary analytical model of ploughing and shearing forces developed here led to the observation that the minimum chip thickness can only be around 0.1 to 0.2 times the
radius of the indenter. Elastic recovery was found to be larger at the the middle of the scratch, which was confirmed with the stress-strain relations derived from the FEM simulations. It was also observed that the spacing between two subsequent scratches can significantly affect the scratched surface quality. These experiments show that the severe ploughing and mid-region ridge features can be avoided by having the scratch pitch to be at least one third of the grit tip radius.

KeywordsTi6Al4V; Machining
Year2022
JournalJournal of Manufacturing Processes
Journal citation82, pp. 543-558
PublisherElsevier
ISSN1526-6125
Digital Object Identifier (DOI)https://doi.org/10.1016/j.jmapro.2022.08.014
Web address (URL)https://www.journals.elsevier.com/journal-of-manufacturing-processes
Publication dates
Print23 Aug 2022
Publication process dates
Accepted10 May 2022
Deposited13 May 2022
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Incipient plasticity in tungsten during nanoindentation: Dependence on surface roughness, probe radius and crystal orientation
Beake B and Goel, S. (2018). Incipient plasticity in tungsten during nanoindentation: Dependence on surface roughness, probe radius and crystal orientation. International Journal of Refractory Metals and Hard Materials. 75, pp. 63-69. https://doi.org/https://doi.org/10.1016/j.ijrmhm.2018.03.020
Designing nanoindentation simulation studies by appropriate indenter choices: Case study on single crystal tungsten
Goel, S., Cross, G., Stukowski, A., Gamsjager, E., Beake, B. and Agrawal, A. (2018). Designing nanoindentation simulation studies by appropriate indenter choices: Case study on single crystal tungsten. Computational Materials Science. 152, pp. 196-210. https://doi.org/https://doi.org/10.1016/j.commatsci.2018.04.044
Current trends and future of sequential micro-machining processes on a single machine tool
Chavoshi, S.Z., Goel, S. and Morantz, P. (2017). Current trends and future of sequential micro-machining processes on a single machine tool. Materials & Design. 127, pp. 37-53. https://doi.org/10.1016/j.matdes.2017.04.057
Cyclic nanoindentation and nano-impact fatigue mechanisms of functionally graded TiN/TiNi film
Faisal NH, Prathuru AK, Goel S, Ahmed R, Droubi MG, Beake BD and Fu YQ (2017). Cyclic nanoindentation and nano-impact fatigue mechanisms of functionally graded TiN/TiNi film. Shape Memory and Superelasticity. 3, pp. 149-167. https://doi.org/10.1007/s40830-017-0099-y
Addressing the discrepancy of finding equilibrium melting point of silicon using MD simulations
Chavoshi SZ, Xu S and Goel S (2017). Addressing the discrepancy of finding equilibrium melting point of silicon using MD simulations. Proceedings of the Royal Society A: Mathematical, Physical and Engineering Sciences. https://doi.org/10.1098/rspa.2017.0084
Influence of temperature on the anisotropic cutting behaviour of single crystal silicon: A molecular dynamics simulation investigation
Chavoshi, S.Z., Goel, S. and Luo, X. (2016). Influence of temperature on the anisotropic cutting behaviour of single crystal silicon: A molecular dynamics simulation investigation. Journal of Manufacturing Processes. 23, pp. 201-210. https://doi.org/10.1016/j.jmapro.2016.06.009
Advances in the surface defect machining (SDM) of hard steels
Rashid, W.B. and Goel, S. (2016). Advances in the surface defect machining (SDM) of hard steels. Journal of Manufacturing Processes. 23, pp. 37-46. https://doi.org/10.1016/j.jmapro.2016.05.007
Influence of microstructure on the cutting behaviour of silicon
Goel, S., Kovalchenko, A., Stukowski, A. and Cross, G. (2016). Influence of microstructure on the cutting behaviour of silicon. Acta Materialia. 105, pp. 464-478. https://doi.org/10.1016/j.actamat.2015.11.046