skip to main content
US FlagAn official website of the United States government
dot gov icon
Official websites use .gov
A .gov website belongs to an official government organization in the United States.
https lock icon
Secure .gov websites use HTTPS
A lock ( lock ) or https:// means you've safely connected to the .gov website. Share sensitive information only on official, secure websites.

Explore Research Products in the PAR
It may take a few hours for recently added research products to appear in PAR search results.


  • NSF Public Access
  • Search Results
  • Analysis of burr formation in finish machining of nickel-based superalloy with worn tools using micro-scale in-situ techniques
Title: Analysis of burr formation in finish machining of nickel-based superalloy with worn tools using micro-scale in-situ techniques
The formation of burrs is among the most significant factors affecting quality and productivity in machining. Burrs are a negative byproduct of machining processes that are difficult to avoid because of a limited understanding of the complex burr formation mechanisms in relation to cutting conditions, including both process parameters and tool condition. Thus, the objective of this work was to characterize burr formation under finish machining conditions via a high-speed, high-resolution in-situ experimental method. Various parameters pertaining to burr geometry such as height, thickness, and initial negative shear angle were measured both during and after cutting. Results showed that varying the conditions of uncut chip thickness, tool-wear, and cutting speed all have a significant effect on burr formation, although certain burr metrics were found to be insensitive with respect to different process conditions because the difference was statistically insignificant. This study provides new insights into the relationships between the workpiece material’s microstructure, machining parameters, and tool condition on both crack formation and propagation/plasticity during burr formation. Using digital image correlation (DIC) and a physics-based process model not previously utilized for burr formation analysis, the displacement and corresponding flow stress were calculated at the exit burr root location. This novel semi-analytical approach revealed that the normalized stress at the exit burr root was approximately equal to the flow stress for a variety of different conditions, indicating the potential for model-based prediction of burr formation mechanics. Finally, this study investigates factors that influence fracture evolution during exit burr formation. It was found that negative exit burrs are a direct result of high strain rate and high uncut chip thickness, which was expected, but also a microstructural size effect and a tool-wear effect, neither of which have been previously reported. By harnessing ultra-high-speed imaging and advanced optical microscopy techniques, this manuscript deals with the fundamentals of burr formation, including new insights into material response at the grain-scale to the loads imposed with both sharp and worn tools.  more » « less
Award ID(s):
2143806
PAR ID:
10488567
Author(s) / Creator(s):
;
Publisher / Repository:
International Journal of Machine Tools and Manufacture, Elsevier
Date Published:
Journal Name:
International Journal of Machine Tools and Manufacture
Volume:
189
Issue:
C
ISSN:
0890-6955
Page Range / eLocation ID:
104030
Subject(s) / Keyword(s):
Burr formation, Inconel 718, Machining, Tool-wear, In-situ characterization, Digital image correlation (DIC)
Format(s):
Medium: X
Sponsoring Org:
National Science Foundation
More Like this
  1. ; ; (, Journal of materials processing technology)
    Budak, Erhan (Ed.)
    This paper presents a generalized cutting force and regenerative chatter stability prediction for the modulated turning (MT) process. Uncut chip thickness is modeled by considering current tool kinematics and undulated (previously generated) surface topography for any given modulation condition in the feed direction. It is found that chip formation is governed by the undulated surface generated in multiple past spindle rotations. Uncut chip thickness is computed analytically in the form of trigonometric functions, and cutting forces are predicted by making use of orthogonal cutting mechanics. Regenerative chatter stability of the process is also modelled. Analytical semi-discretization-based solution is developed to accurately predict the stability lobe diagrams (SLDs) of the MT process. Predicted stability lobes are validated through numerical time-domain simulations and experimentally via orthogonal (plunge) turning tests. It is found that as compared to conventional single-point continuous turning, regenerative stability of MT exhibits multiple (3) regenerative delay loops and long out-of-cut duration in-between tool engagement stabilizes the process to reach up to 2x higher stable widths/depths as compared to the conventional continuous turning. 
    more » « less
  2. ; ; (, American Society of Mechanical Engineers)
    Using direct high-speed imaging, we study the transition between different chip formation modes, and the underlying mechanics, in machining of ductile metals. Three distinct chip formation modes — continuous chip, shear-localized chip, and fragmented chip — are effected in a same material system by varying the cutting speed. It is shown using direct observations that shear-localized chip formation is characterized by shear band nucleation at the tool tip and its propagation towards the free surface, which is then followed by plastic slip along the band without fracture. The transition from shear-localized chip to fragmented chip with increasing cutting speed is triggered by crack initiation at the free surface and propagation towards the tool tip. The extent to which crack travels towards the tool determines whether the chip is partially fragmented or fully fragmented (discontinuous). It is shown that shear localization precedes fracture and controls the crack path in fragmented chip formation. Dynamic strain and strain-rate fields underlying the each chip formation mode are quantified through image correlation analysis of high-speed images. Implications for using machining as an experimental tool for fundamental studies of localization and shear fracture in ductile metals are also discussed. 
    more » « less
  3. ; ; ; ; (, The International Journal of Advanced Manufacturing Technology)
    Abstract In recent years, semiconductors, electronics, optics, and various other industries have seen a significant surge in the use of sapphire materials, driven by their exceptional mechanical and chemical properties. The machining of sapphire surfaces plays a crucial role in all these applications. However, due to sapphires’ exceptionally high hardness (Mohs hardness of 9, Vickers hardness of 2300) and brittleness, machining them often presents challenges such as microcracking and chipping of the workpiece, as well as significant tool wear, making sapphires difficult to cut. To enhance the machining efficiency and machined surface integrity, ultrasonic vibration-assisted (UV-A) machining of sapphire has already been studied, showing improved performance with lower cutting force, better surface finish, and extended tool life. Scribing tests using a single-diamond tool not only are an effective method to understand the material removal mechanism and deformation characteristics during such UV-A machining processes but also can be used as a potential process for separating IC chips from wafers. This paper presents a comprehensive study of the UV-A scribing process, aiming to develop an understanding of sapphire’s material removal mechanism under varying ultrasonic power levels and cutting tool geometries. In this experimental investigation, the effect of five different levels of ultrasonic power and three different cutting tool tip angles at various feeding depths on the scribe-induced features of the sapphire surface has been presented with a quantitative and qualitative comparison. The findings indicate that at feeding depths less than 6 μm, UV-A scribing with 40–80% ultrasonic power can reduce cutting force up to 50% and thus improve scribe quality. However, between feeding depths of 6 to 10 μm, this advantage of using ultrasonic vibration gradually diminishes. Additionally, UV-A scribing with a smaller tool tip angle (60°) was found to lower cutting force by 65% and improve scribe quality, effectively inhibiting residual stress formation and microcrack propagation. Furthermore, UV-A scribing also facilitated higher critical feeding depths at around 10 μm, compared to 6 μm in conventional scribing. 
    more » « less
  4. ; ; ; ; ; (, Manufacturing letters)
    The machining of nickel-based superalloys such as Inconel 718 still poses a great challenge. The high strength and temperature resistance of these materials lead to poor machinability, resulting in high process forces and extensive tool wear. However, this wear is stochastic when reaching a certain point and is di cult to predict. To generate consistent wear conditions, the tool wear can be decoupled from the milling process by creating artificial wear using grinding. In this paper, a multi-axis approach for decoupling tool wear is presented and analyzed. Therefore, scanning electron microscope images of di erent wear states – worn and artificially worn – are analyzed. In addition, the occurring process forces of naturally and contrived worn inserts are compared in orthogonal cutting experiments as an analogy setup. Finally, a finite element analysis using a novel methodology for segmenting relevant cutting edge sections using digital microscope images provides qualitative insights on the influence of different wear conditions. 
    more » « less
  5. ; ; ; ; (, Manufacturing Letters (special collection Proceedings of SME North American Manufacturing Research Conference))
    Nickel-based superalloys belong to a category of material employed for extreme conditions and exhibit high strength properties at elevated temperatures that result in poor machinability. Machining such di cult-to-cut materials like Inconel 718 leads to a high rate of tool wear, and therefore trochoidal milling toolpath is used to improve productivity and tool life. The current study analyzes the evolution of the flank wear area of the tool during trochoidal milling of Inconel 718 using an image processing methodology. It is attempted by performing experimental studies until tool failure occurs at several cutting conditions. The machining is performed through several iterations on an identical cutting path, and the number of iterations to failure is recorded. The microstructural image of a flank wear area is captured upon each iteration and processed using an image processing algorithm. It is realized that the evaluation of flank wear area can be an e ective parameter to analyze tool wear. Also, the image processing methodology works e ectively and can be extended during real-time machining. 
    more » « less
  • Citation Formats
  • MLA
  • APA
  • Chicago
  • BibTeX
  • Save / Share this Record
  • Send to Email