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Procedia CIRP 00 (2019) 000–000

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Procedia CIRP 00 (2019) 000–000

ScienceDirect
ScienceDirect www.elsevier.com/locate/procedia

5th
Procedia CIRP CIRP
00 (2017)
Procedia CSI
(2020)2020
000–000
CIRP 87 137–141
www.elsevier.com/locate/procedia

Influence of built up edge on the surface topography of Ti-15Mo

5th CIRP CSI 2020
D. Paris , L.B. Pivottob, C.E.H. Venturaa*, A.Í.S. Antoniallia
a

a Influence of28th
built upDesign
CIRP edgeConference,
on the surface topography
May 2018, Nantes, Franceof Ti-15Mo
Department of Mechanical Engineering, Federal University of São Carlos, Rod. Washington Luís km 235, São Carlos 13565-905, SP, Brazil
b
São Carlos School of Engineering, University of São Paulo, Av. Trabalhador São Carlense 400, São Carlos 13566-590, SP, Brazil
A new methodology D. Paris ,to analyze
Pivotto the functional
Ventura *,and physical
Antonialliarchitecture of
a b a a
L.B. , C.E.H. A.Í.S.
* Corresponding author. Tel.: +55 16 33066857; fax: +55 16 33518286. E-mail address: ventura@ufscar.br

existing
Departmentproducts
a
for anFederal
of Mechanical Engineering,
b
assembly
University of Sãooriented product
Carlos, Rod. Washington family
Luís km 235, São Carlosidentification
13565-905, SP, Brazil
São Carlos School of Engineering, University of São Paulo, Av. Trabalhador São Carlense 400, São Carlos 13566-590, SP, Brazil
*Abstract
Corresponding author. Tel.: +55 16 33066857; fax: +55 16 33518286. E-mail address: ventura@ufscar.br
Paul Stief *, Jean-Yves Dantan, Alain Etienne, Ali Siadat
Titanium alloys
École have beenSupérieure
Nationale increasingly used
d’Arts in biomedical
et Métiers, applications
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ParisTech, to their
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Augustin resistance,
Fresnel, non-toxicity,
Metz 57078, France and low
modulus of elasticity. This latter property leads to intense material deformation during cutting and contributes to the formation of built up edge,
Abstract
which changes tool geometry and chip formation, altering workpiece surface quality. Its instability should also be taken into account, as it
*contributes
Corresponding
to aauthor. Tel.: +33 3 87
high dispersion of 37 54 30; E-mail
roughness address:
results. paul.stief@ensam.eu
Considering the relevance of such effects in machining of a beta titanium alloy, this paper
Titanium
proposes aalloys have been increasingly
characterization of the built used in biomedical
up edge applications
formed during turning due to their mechanical
of Ti-15Mo and corrosion
and the correlation of its resistance, non-toxicity,
geometry with differentand low
surface
modulus
roughnessofparameters.
elasticity. This latter results
Obtained property leadsthat
show to the
intense material
effective rakedeformation during
angle generated bycutting andupcontributes
the built to the
edge changes formation
within of built
a narrow rangeupbut
edge,
its
which
increasechanges tool to
contributes geometry and chip
lower reduced formation,
peak altering
height values workpiece
obtained surface
from the quality. Its instability
Abbott-Firestone curve. should also be taken into account, as it
Abstract
contributes to a high dispersion of roughness results. Considering the relevance of such effects in machining of a beta titanium alloy, this paper
proposes a characterization of the built up edge formed during turning of Ti-15Mo and the correlation of its geometry with different surface
Inroughness
today’s business environment,
parameters. the trend
Obtained results showtowards more
that the product
effective variety
rake angleand customization
generated is unbroken.
by the built up edge Due to this
changes development,
within the need
a narrow range but of
its
agile andThe
© 2020
increase reconfigurable production
Authors.toPublished
contributes lower systems
by Elsevier
reduced emerged
B.V.
peak height to obtained
values cope withfromvarious products and product
the Abbott-Firestone curve.families. To design and optimize production
systems as open
This is an well access
as to choose
article the optimal
under the CCproduct
BY-NC-ND matches, product
license analysis methods are needed. Indeed, most of the known methods aim to
(http://creativecommons.org/licenses/by-nc-nd/4.0/)
© 2020aThe
analyze Authors.
product or onePublished by Elsevier
product family on theB.V.
physical level. Different product families, however, may differ largely in terms of the number and
This is an open
Peer-review access
under article under
responsibility the scientific
of the CC BY-NC-ND license
committee (http://creativecommons.org/licenses/by-nc-nd/4.0/)
of the 5th
nature of components. This fact impedes an efficient comparison andCIRP
choiceCSIof2020
appropriate product family combinations for the production
Peer-review
© 2020 The under responsibility
Authors. Published of Elsevier
by the scientific
B.V. committee of the 5th CIRP CSI 2020
system. A new methodology is proposed to analyze existing products in view of their functional and physical architecture. The aim is to cluster
Keywords:
This
these Built
is an open
products inup edge;
access
new Surfaceunder
article
assembly roughness;
the CC
oriented Beta titanium
BY-NC-ND
product alloy
families license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
for the optimization of existing assembly lines and the creation of future reconfigurable
assembly systems. Based on Datum Flow Chain, the physical structure of the products is analyzed. Functional subassemblies are identified, and
Peer-review under responsibility of the scientific committee of the 5th CIRP CSI 2020
a functional analysis is performed. Moreover, a hybrid functional and physical architecture graph (HyFPAG) is the output which depicts the
similarity between product families by providing design support to both, production system planners and product designers. An illustrative
Keywords: Built up edge; Surface roughness; Beta titanium alloy
example of a nail-clipper is used to explain the proposed methodology. An industrial case study on two product families of steering columns of
1. Introduction Beta titanium alloys usually present significant contents of
thyssenkrupp Presta France is then carried out to give a first industrial evaluation of the proposed approach.
© 2017 The Authors. Published by Elsevier B.V.
niobium, tantalum and molybdenum, elements which are
Despite their high manufacturing cost, in the last few absolutely
Peer-review under responsibility of the scientific committee of the 28th CIRP Design Conference harmless 2018.
to human health and help to decrease the
decades, titanium alloys have been extensively applied in phase transition temperature and stabilize the body-centered
1. Introduction Beta titanium alloys usually present significant contents of
medical Assembly;
Keywords: devices Design
because
method;ofFamily
theiridentification
biocompatibility [1]. cubic structure (BCC) of titanium. These alloys have high
niobium, tantalum and molybdenum, elements which are
However, aluminium and vanadium, present in Ti-6Al-4V, the mechanical strength and resistance to corrosion, good
Despite their high manufacturing cost, in the last few absolutely harmless to human health and help to decrease the
most common among all titanium alloys, are toxic elements conformability and considerably lower elastic modulus than
decades, titanium alloys have been extensively applied in phase transition temperature and stabilize the body-centered
and may be associated to several diseases [2]. alfa (with hexagonal close packed structure, HCP) or alfa-beta
medical
1. Introductiondevices because of their biocompatibility [1]. cubic
of structurerange
the product (BCC) ofcharacteristics
titanium. These alloys haveand/or
high
(HCP+BCC) titaniumand alloys [4]. manufactured
However, aluminium and vanadium, present in Ti-6Al-4V, the mechanical strength
Another important feature to be considered on the assembled in this system. In this context, the main challenge in and resistance to corrosion, good
most
Duecommon
production to of theamong
fast alldevelopment
implants istitanium
the elasticalloys, are
the toxic
inmodulus (orelements
domain Young of conformability
Due to and
modelling and considerably
the analysis
chemical now notlower
is affinity with elastic
to copemodulus
onlycommonly than
usedsingle
with tool
and may
communication be
modulus), which associated
andshall to
an be several
as low
ongoing diseases [2].
as the
trend bone’s. Thisandis products,
of digitization alfa (with hexagonal
materials,a machining close packed
of titanium
limited product range or structure,
alloys HCP)
is usually
existing or alfa-beta
productassociated
families,
necessary to avoid
digitalization, the stress shielding
manufacturing enterprises phenomenon, related to but (HCP+BCC)
withalso
diffusion titanium
wear. alloys and
Moreover, [4].into reason ofproducts
their lowtothermal
Another important feature to be are facing important
considered on the to be able to analyze compare define
the inhomogeneous
challenges in today’sdistribution
market of mechanical stresses,
environments: a which new
continuing conductivity,
product which increases
families. It can be the temperature
observed that of the tool
classical and
existing
production of implants is the elastic modulus (or Young Due to the chemical affinity with commonly used tool
may promote
tendency towards the reduction
looseningofofproductthe implant or even times
development new bone and promotes
product thermoplastic
families are instability,
regrouped in cutting
function of force fluctuations
clients or features.
modulus), which shall be as low as the bone’s. This is materials, machining of titanium alloys is usually associated
fractures [3].
shortened and vibration, which damage surface integrity, can tooccur.
necessaryproduct
to avoidlifecycles.
the stress In addition,phenomenon,
shielding there is an increasing
related to However, assembly
with diffusion wear.oriented
Moreover, product families
in reason of are hardly
their find.
low thermal
demand of customization, being at the same time in a global These features, added level,
to their outstanding mechanical
the inhomogeneous distribution of mechanical stresses, which conductivity, which increases the temperature of the tool two
On the product family products differ mainly in and
competition with competitors all over the
may promote the loosening of the implant or even new bone world. This trend, main characteristics:
promotes thermoplastic(i) the number of
instability, components
cutting and (ii) the
force fluctuations
which
fracturesis [3].
inducing the development from macro to micro type
and of components
vibration, which(e.g.damage
mechanical,surfaceelectrical, electronical).
integrity, can occur.
2212-8271 © 2020 The Authors. Published by Elsevier B.V.
markets, results in diminished lot sizes due to augmenting Classical methodologies considering
These features, added to their outstanding mechanical
This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/) mainly single products
product varieties
Peer-review (high-volume
under responsibility of theto low-volume
scientific committeeproduction)
of the 5th CIRP[1].CSI 2020
or solitary, already existing product families analyze the
To cope with this augmenting variety as well as to be able to product structure on a physical level (components level) which
identify
2212-8271 possible
© 2020 The optimization
Authors. Publishedpotentials in the existing
by Elsevier B.V. causes difficulties regarding an efficient definition and
This is an open
production access article
system, under the CCtoBY-NC-ND
it is important license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
have a precise knowledge comparison of different product families. Addressing this
Peer-review under responsibility of the scientific committee of the 5th CIRP CSI 2020
2212-8271 © 2020 The Authors. Published by Elsevier B.V.
This is an©open
2212-8271 2017access article Published
The Authors. under theby CC BY-NC-ND
Elsevier B.V. license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer-review
Peer-review under
under responsibility
responsibility of scientific
of the the scientific committee
committee of the of theCIRP
28th 5th CIRP
DesignCSI 2020 2018.
Conference
10.1016/j.procir.2020.02.098
138 D. Paris et al. / Procedia CIRP 87 (2020) 137–141
2 Author name / Procedia CIRP 00 (2019) 000–000

properties even at high temperatures, severely impair their m/min and 104 m/min), while feed rate f = 0.1 mm/rev and
machinability [5]. depth of cut ap = 0.5 mm were kept constant.

In order to face all these difficulties, cutting tools must
present considerably high hot hardness, wear resistance,
fracture toughness and chemical stability. Uncoated cemented
tungsten carbide is the main tool material employed in the
machining of titanium alloys, as it shows out to be more
advantageous than other materials such as ceramic, cubic
boron nitride (CBN) or polycrystalline diamond (PCD) [6].
The use of cutting fluids and low cutting speeds (compared to
those usually employed on the machining of stainless steels,
for example) is also recommended [7].
Arrazola et al. [8] have compared the machinability of Ti-
6Al-4V alfa-beta titanium alloy against Ti-5553 near-beta
titanium alloy (5 wt% Mo). They concluded that the latter
presents a poorer machinability, as a lower cutting speed was
necessary to achieve the same tool life. Besides the
considerable molybdenum content, its higher ultimate tensile
strength may explain the obtained results. Hatt et al. [9] have
compared tool wear in the machining of Ti-54M (alfa-beta
alloy) and Ti-6246 (beta alloy). They have observed for the
first alloy both flank and crater wear caused by abrasion,
whilst for the latter, a combination of different mechanisms
which led to plastic deformation and breakage was noted. Tool
wear has also a significant influence on surface integrity. Che-
Haron [10] have observed that surface roughness increases
with higher values of cutting speed when machining Ti-6Al-
2Sn-4Zr-6Mo alfa-beta alloy, probably as a consequence of
the modification of the cutting edge as an effect of flank and
crater wear, as well as edge chipping, caused by abrasion,
adhesion and diffusion mechanisms.
Regarding tool geometry, Wang and Liu [11]
recommended the use of chamfered edges for better results in
machining of titanium and nickel-based alloys, because it has
proved to strengthen the cutting edge, avoiding edge chipping.
Cutting tests were performed in workpieces with diameter
of 35 mm and four sections, so that images of the cutting edge
could be acquired and surface roughness could be evaluated
after a cutting pass of 30 mm. For each level of cutting speed,
a new insert was applied in a total axial length of 360 mm,
which means that three workpieces (12 sections) were used
for each cutting speed. The characterization of the built up
edge formed during cutting through the measurement of
effective rake angle and edge radius (Fig. 1b), as well as the
assessment of the respective turned surface through the
measurement of skewness, kurtosis and parameters of the
Abbott-Firestone curve, like reduced peak height and reduced
valley depth, were performed in a microscope Alicona
InfiniteFocus SL.
It is well known that built up edge is unstable, but
considering that no tool wear was observed during cutting, it
was assumed that its shape has approximately the same
characteristics during each pass (axial length of 30 mm). In an
attempt to correlate its geometry with surface characteristics,
roughness parameters were measured at the end of each
section in two distinct regions of the turned surface and the
average value was used to construct the graphs. To analyze
the geometric characteristics of the built up edge, average
values of 20 profiles positioned perpendicular to the main
cutting edge (edge radius and cutting edge angle should be
considered) were obtained (Fig. 1a). It is important to
highlight that irregular formed or broken built up edges were
not considered in the analysis, so that less than 12 points were
used in the graphs. Examples of the cutting edges after the
first cutting pass with different cutting speeds are
demonstrated in Fig. 1c.

Although built up edge plays an important role in

machining of beta titanium alloys because of their low elastic
modulus and high hardening coefficient, it is not often
reported and its effect on surface quality is not discussed.
Considering this, an analysis of the correlation between built
up edge characteristics and surface roughness parameters is
proposed in this work, which should contribute to explain the
variability of roughness results when built up edge is present.

2. Material and methods

In order to investigate the influence of built up edge

geometry on surface roughness, turning tests in the titanium
alloy Ti-15Mo were carried out with the application of flood
coolant (10% emulsion) and an uncoated cemented tungsten
carbide insert DNMG110408, ISO grade S20. The insert was
mounted in a tool holder DDNNN 2020K 11, which provides
a cutting edge angle of 62.5°, a rake angle of -7° (due to the
presence of chip breaker, the effective rake angle corresponds Fig. 1. Geometry of built up edge: (a) extracted profiles, (b) geometric
to +13°) and a relief angle of +7°. The tool holder was placed
parameters, and (c) examples of cutting edges after the first cutting pass (axial
in a lathe Imor PRN-320, with maximum rotation speed of
length of 30 mm) with vc = 54 m/min and 104 m/min.
1500 min-1. Cutting speed was varied in two levels (vc = 54
 D. Paris et al. / Procedia CIRP 87 (2020) 137–141 139
Author name / Procedia CIRP 00 (2019) 000–000 3

3. Results and discussion or cutting speed, but Ssk is always positive and Sku is always
higher than 3, which characterizes steep peaks and valleys.
Built up edge is formed due to the adhesion and work
hardening of chips on the tool rake face and is commonly
related to low cutting speeds. In the case of titanium alloys,
low values of elastic modulus contribute to the deformation of
the material and favor built up edge formation. During
cutting, such structure corresponds to the actual cutting edge
and substitutes the original tool geometry, altering material
removal characteristics, because of changes in the effective
rake angle and edge radius.

Although built up edge is usually unstable and can break

during cutting, its geometry is responsible for chip formation,
influencing surface roughness. Positive rake angles and large
edge radii were the main characteristics observed during
turning of Ti-15Mo with uncoated cemented tungsten carbide
inserts.

As built up edge formation is unstable, even with the same

cutting conditions the same geometry cannot be guaranteed
after cutting each section (axial length of 30 mm) because of
release of particles, changes in tool-workpiece contact
characteristics, entry and exit of the tool. It is assumed,
however, that, mainly at the final part of each section, an
approximate geometry is maintained.
Fig. 3. Variation of skewness with different (a) effective rake angles and (b)
Besides some vibration occurred during the process, two edge radii (f = 0.1 mm/rev, ap = 0.5 mm).
factors contribute to an irregular workpiece surface (Fig. 2):
fragmented particles of built up edge, which adhere to the
surface; and a blunt cutting edge, which makes it more
difficult to the tool to penetrate and shear the material,
causing intense plastic deformation and chip side flow,
verified by the presence of protuberances near the grooves.

Fig. 2. Surface obtained after turning with f = 0.1 mm/rev, ap = 0.5 mm and
different cutting speeds.
Due to the random positioning of the irregularities, the
turned workpieces were characterized by means of surface
(not profile) roughness parameters. Figs. 3a and 3b show the
values of skewness (Ssk), while Figs. 4a and 4b demonstrate
the values obtained for kurtosis (Sku), both dependent on
effective rake angle and edge radius of the built up edge. No
clear trend could be noted for the variation of edge geometry
Fig. 4. Variation of kurtosis with different (a) effective rake angles and (b)
edge radii (f = 0.1 mm/rev, ap = 0.5 mm).
Due to the presence of adhered and deformed material on
the surface and the occurrence of some vibration during the
process because of high elongation of the material before
shearing, parameters of the Abbott-Firestone curve were
chosen to measure peaks and valleys beyond the core surface
roughness. Thus, an additional assessment was performed
140 D. Paris et al. / Procedia CIRP 87 (2020) 137–141
4 Author name / Procedia CIRP 00 (2019) 000–000
through the reduced peak height (Spk) and the reduced valley
depth (Svk), demonstrated in Figs. 5 and 6, respectively. Both
parameters are shown in function of the effective rake angle
and the edge radius after built up edge formation.
Fig. 5. Variation of reduced peak height with (a) different effective rake
angles and (b) edge radii (f = 0.1 mm/rev, ap = 0.5 mm).
Fig. 6. Variation of reduced valley depth with (a) different effective rake
angles and (b) edge radii (f = 0.1 mm/rev, ap = 0.5 mm).
Although the variation of the effective rake angle after the
formation of built up edge occurred in a narrow range and the
correlation coefficients present relative low values
(R2 ~ 0.63), an increase in this parameter produced a
decreasing trend of Spk and Svk values for both cutting
speeds. A more positive geometry and a consequent increase
of shearing angle lead to a reduction of chip deformation and
explain the lower values of the measured roughness
parameters. The tests carried out with a higher cutting speed
produced a worse surface, with higher values of Spk and Svk,
what can be associated with higher temperatures involved in
the process, which favors material deformation and reduces
the strength of the built up edge.
Differently, a broad range of edge radii was observed after
the tests, but no evident influence of such characteristic on the
measured roughness parameters could be noted, even though
an intense material deformation and chip side flow were
expected with larger radii. Apparently, the edge tip was not
consistent during cutting, which can have constantly altered
the built up edge-workpiece contact geometry.
4. Conclusions
Based on the obtained results it can be concluded that built
up edge affects surface roughness irregularly. Large built up
edge radii are not stable and consequently do not demonstrate
any trend with the measured roughness parameters.
Contrarily, an increase in the resultant effective rake angle
after built up edge formation causes a reduction of reduced
peak height and reduced valley depth. Additionally, a higher
value of cutting speed leads to a reduced surface quality.
The observations are valid for the range of tested
conditions and cannot be generalized. More experiments
should be carried out in order to better understand the effects
of cutting parameters on surface properties.
Acknowledgements
The authors would like to thank the Brazilian Federal
Agency for the Support and Evaluation of Graduate Education
(CAPES).
This work was supported by the São Paulo Research
Foundation (FAPESP) (grant numbers 2015/15622-2,
2017/12309-7 and 2017/12304-5).
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