Physics-based Machining of Aerospace

Materials

Dr. Suhas Joshi

Professor, Department of Mechanical Engineering
Indian Institute of Technology Bombay, Mumbai – 400076
Email: ssjoshi@iitb.ac.in
 Plan of
Presentation

•Introduction
•Titanium alloys, their properties and machining difficulties
•Theme and Methodology of the work
•Chip segment morphology
•Mechanics of a chip segment formation
•Chip and shear band microstructure
•Correlation between machinability and microstructure
•Summary and conclusions

2
 Physics-based Machining

Physics-based Machining refers to understanding -

• several microscopic phenomena that occur

during machining,
• the effect of these phenomena on a chip
segment and grain deformation,
• the effect on physical and mechanical properties
of resulting surfaces,
• the consequent machinability or quality of
machined surface.

3
 Physics-based Machining

Tool – work interface

Face On Tool
Intense Friction and
wear, heat generation
Tool
On Work surface
Chip
Material separation,
severe deformation,
Un-deformed
machining affected
chip thickness Flank
zone.
surface
Machined
surface

Work

Shear plane/zone
Chip-tool interface
Largest energy consumer
Intense 2-body / 3-body Friction
Strain: 2-8
Crater wear
Temperature: 200 – 1100oC
Determines position of shear zone
Strain rate: 103 - 106 s-1
4
 Titanium Alloys Properties

•High strength-to-weight ratio (Light weight)

Ti6Al4V HSLA steel

Tensile strength 950 760
(MPa)
Density(Kg/m3 ) 4300 7800

•Maintains strength at higher temperature of 440 °C

•Good corrosion resistance

•Compatibility with composites

•Inertness to human body

5
 Properties of Titanium alloys

α+β

Alpha alloy Alpha + Beta alloy Beta rich (Alpha + Beta alloy)
Alpha Alpha + Beta Beta rich alloy

• Medium strength • Medium to high • High strength, low

• Not heat treatable strength ductility
• Good creep and • Heat treatable and • Heat and weld treatable
corrosion resistance formable • Good formability
 Applications of Titanium Alloys

Impeller Piston Ultra light weight bolt

Bearing housing
Fasteners Airframe structure
of gas turbine

7
Properties causing Difficulties in Machining

• High machining • High tool wear • High cutting

temperature • Chemical wear forces
• Tool melting • Tool breakage
• Ti alloy 15 W/m °C,
• Adhesion
Steel 43 W/m °C

Low Thermal High High strength

conductivity Reactivity at high temp.

• Chatter • Shear band

• Poor surface formation
finish • Cyclic load on
• Ti alloy 110 GPa, Steel
210 GPa the tools

Low elastic Segmented

modulus chips

8
 Theme of Physics-based Machining

Chip Chip
segment segment
Morphology deformation

Correlation Shear band

between Physics-
spacing
microstructural based
deformation and Machining and
Machinability thickness

Grain Grain
deformation transportation
in machined and
surfaces deformation

9
 Applications of Titanium Alloys

Impeller Piston Ultra light weight bolt

metallurgyfordummies.com
www.mvagusta.net
www.topcast.it

Bearing housing
Fasteners Airframe structure
of gas turbine

www.mvagusta.net www.mvagusta.net www.airbus.com

10
 Orthogonal Machining of Ti64 alloy

Deformation zones in machining

Characteristics of machining
•
• Segmented
• Strain
chips
  ~ 4 to 6 Chip

• Strain rates ~ 105/s

• Machining Temp Shear
bands
~200 °C to 600 °C 0.5
Tool
Phase diagram Ti-Al
Deformation
of grains

Shear
zone Machining
Work affected
piece zone

Microstructural changes in
• Primary deformation or shear zone
• Machining affected zone

11
http://www.calphad.com
 Distinguishing feature of Ti64 machining

 •Main characteristic of Ti64 machining are the adiabatic shear

bands (ASB)
• Strain ~ 4 to 6
• Strain rates ~ 105/s
• Temp ~200 °C to 600 °C
• Formed in ~ 50
•High strain rate ABSs can be also produced by
1. Orthogonal Machining (OM)
2. Split-Hopkinson (SH) Experiments on Hat shaped samples
 Issues in machining titanium alloys (microstructural perspective)
SEM image of chip Optical image of chip
Shear band
shear
Segmented band
chip

shear
Fracture
band

shear
band

a
Work

Formation of shear band causes

• Fluctuation in cutting forces
• Non uniform material deformation 13
 Plan of Research
Shear band
Mist jet
Thermally thickness
LN2 enhanced
Spacing
between
Room Machining shear band
Temp. environment
Physics of Grain size
α-alloy deformation
α+β Compositional in machining
alloy Grain
variation
deformation
β-rich
alloy Segment
Processing
Speed shape
parameters
Segment
Feed dimensions

Input Output

microstructure machinability
linkage 14
 Experimental set up
Plain strain condition
Four jaw chuck
Quick stop chip freezing device
Thin pipe of large dia.
1 mm
Fulcrum  𝐴
Quick
Workpiece withdrawal of
tool
  93mm Mounted sample
Insert
Epoxy
Tool Frozen
Cutting edge mould
chip root
larger than pipe
thickness Feed
Shear
bands
𝐵 𝐶
  𝐵
  2
  1
Tool Shear
holde pin
r

Work piece c. Quick withdrawal

Machining
of tool
affected
zone

quick stop device animation fina video2. autostreamwmv.wmv 15

 Properties of three titanium alloys
α alloy α+ alloy  rich alloy
 

  phase
  phase
  phase   phase

Comparative properties and applications of titanium alloys

  Alloy Type
alloy + alloy rich () alloy
Properties Medium strength, Not heat Medium to high strength High strength, low ductility
treatable, Good creep and Heat treatable and Heat treatable and weldable
corrosion resistance formable Good formability, high
fatigue strength
Applications High temperature low strength alloys are used for high High fatigue strength and
applications such as gas turbine strength applications like formability is required such
casing, rings, structural members in aircraft gas turbine disks, as automobiles, motorcycles,
hot spots, chemical processing blades, airframe structural and sports and leisure goods
equipment along with cryogenic parts, fasteners such as golf clubs
applications
16
 Microstructural evolution in adiabatic shear band
SE image of alpha alloy
Chip

Shear band
Highly elongated • Grains undergo large deformation
grains inside
shear band
• Twinning is not observed.
• Dislocation slip is dominant deformation
Grain
deformation mechanism.
In between • Rigid body rotation of grains observed
shear band
Free chip
surface
Tool

Shear
Grain direction
rotation

Grain deformation
before formation
of shear band 17
Microstructural evolution in adiabatic shear band
IPF Image quality map
Chip Chip

Region under
consideration

Shear
band

Shear
band Tool

Shear direction

Shear zone
Shear zone

Work piece
Work piece

18
 Microstructural changes in the shear band
SEM Image IPF EBSD scan
image Quality Magnified image of shear band
step size 40 nm
Black region showing
deformed grains
Grain elongation
and subdivision Shear band
region
Shear
band

Chip segment

• Regions surrounding the shear band shows

grains undergo subdivision and
Shear deformation
band
before the formation of shear band.
19
 TEM study inside the shear band
Grains with
Region outside
heavy dislocations
Shear band Edge of hole made by
twin jet polishing

Shear band
region b.

Magnified
Deformed image
grain

c.
SAD

a. d.

• Deformed grains inside the shear band and region of high dislocation
density points against dynamic recrystallization
20
 Observation of dislocation density by etch pit method
at shear band region

• Polished chip is etched for 10

minute.
• A valley formed at the shear
band region shows higher material
removal from that region.
• This indicates shear band region is
a strained one with high
dislocation density

21
 Comparison of observations with previous TEM studies

Experiments in this work Meyer and Pak Perez-prado, Acta mater.

(1995,2001,2003) Acta mater. 49 (2001)
2905–2917

Observations • No dynamic • Equi-axed grains with dia. • Cell size 0.2 µm, New
recrystallized grains 0.05-0.2 µm. dislocation free grains
are observed in EBSD • Low dislocation density. was not observed in
• Inside shear band, a ring
scan and TEM like pattern produced by TEM,
• TEM reveals grains many crystallographic • Only dynamic recovery
with high dislocation orientation is apparent. occurred. Appearance
densities in the shear • Diahedral angle (~120)at of ring like pattern in
band. grain boundary triple the center of shear
• Grains surrounding point indicate that the band is not enough
shear band are highly boundaries have energies evidence for
consistent with high
elongated and have angles recrystallization.
shown sub-grain • Recrystallization is not
formation observed

Conclusions No DRX DRX No DRX

22