Abstract
Fe-based amorphous alloy, a new-type material, was developed as a special-purpose welt overlay for remanufacture. It was deposited on the worn-out part for resuming and upgrading part performance. The microstructure characteristics of the overlay was characterized, including microstructure, phase composition, thermostability, and microhardness. In order to get a comprehensive insight to the machining process of amorphous overlay, this paper presents an experimental investigation into the effect of various machining parameters and tool geometry (Edge) on the surface roughness, tool wear, chip morphology, and surface damage. Comparing larger rake angle of 15°and smaller nose radius of 0.4 mm with 5° and 0.8 mm at the same cutting parameters, we found that larger rake angle of 15° and smaller nose radius of 0.4 mm increased the R a surface roughness parameter. In the tests, crater wear was not observed, and the friction and wear on the minor cutting edge wear were heavy due to the spring back of the machined surface. In brief,abrasion, adhesion, fatigue, and chipping are the main wear mechanism. As the feed rate reduced and the depth of cut increased (from feed rate = 0.06 mm/rev and depth of cut = 0.3 mm to feed rate = 0.09 mm/rev and depth of cut = 0.2 mm), a number of physical changes occurred in the chip including reduced distance between serrations, increased shear band angle, and changed chip morphology from spiral to ribbon shape. The results show that strain and strain rate rises in the chips’ inside with the increase in cutting temperature. When the thermal softening exceeded strain hardening, the shear resistance decreased rapidly. Thus, the free surface of the chip presents the nodular and lamella structure. It was noted that specimens generated by larger rake angle of 15° and smaller nose radius of 0.4 mm showed poor surface roughness as well as extensive surface damage.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Wang YG, Yan XP, Li B, Tu GC (2012) The study on the chip formation and wear behavior for drilling forged steel S48CS1V with TiAlN-coated gun drill. Int J Ref Met Hard Mat 30(1):200–207
Gill SS, Singh J, Singh H, Singh R (2011) Investigation on wear behaviour of cryogenically treated TiAlN coated tungsten carbide inserts in turning. Int J Mach Tools Manuf 51(1):25–33
Castanho JM, Vieira MT (2003) Effect of ductile layers in mechanical behavior of TiAlN thin coatings. J Mater Process Technol 143–144(20):352–357
Hogmark S, Olsson M (2005) Wear mechanisms of HSS cutting tools. SME Tech Paper 1:1–14
Venkatesh VC, Zhou DQ, Xue W, Quinto DT (1993) A study of chip surface characteristics during the machining of steel. Ann CIRP-Manuf Technol 42(1):631–636
Lorentzon J, Järvstråt N, Josefson BL (2009) Modelling chip formation of alloy 718. J Mater Process Technol 209(10):4645–4653
Töenshoff HK, Arendt C, Amor RB (2000) Cutting hardened steel. Ann CIRP Manuf Technol 49:547–566
Özel T, Hsu HK, Zeren E (2005) Effects of cutting edge geometry, workpiece hardness, feed rate and cutting speed on surface roughness and forces in finish turning of hardened AISI H13 steel. Int J Adv Manuf Technol 25(3–4):262–269
Özel T, Karpat Y (2005) Predictive modeling of surface roughness and tool wear in hard turning using regression and neural networks. Int J Mach Tools Manuf 45(4–5):467–497
Bhushan RK, Kumar S, Das S (2010) Effect of machining parameters on surface roughness and tool wear for 7075 Al alloy SiC composite. Int J Adv Manuf Technol 50(5–8):459–469
Ponnambalam V, Poon SJ, Gary JS (2004) Fe-Based bulk metallic glasses with diameter thickness larger than one centimeter. J Mater Res 19:1320–1323
Thiele JD, Melkote SN (1999) Effect of cutting edge geometry and workpiece hardness on surface generation in the finish hard turning of AISI 52100 steel. J Mater Process Technol 94(2–3):216–226
Singh D, Rao PV (2007) A surface roughness prediction model for hard turning process. Int J Adv Manuf Technol 32(11–12):1115–1124
EL-Wardany TI, Kishawy HA, Elbestawi MA (2000) Surface integrity of die material in high speed hard machining. Part 2: microhardness variation and residual stress. Trans ASME-J Manuf Sci Eng 122(11):632–641
Bermingham MJ, Kirsch J, Sun S, Palanisamy S, Dargusch MS (2011) New observation on tool life, cutting forces and chip morphology in cryogenic machining Ti-6Al-4V. Int J Mach Tools Manuf 51(6):500–511
Lin KL, Chao WH, Wu CD (1997) The performation and degradation behavior of the TiAlN/interlayer coating on the drill. Surf Coat Technol 87(3):274–284
Simoneau A, Ng E, Elbestawi MA (2006) The effect of microstructure on chip formation and surface defects in microscale, mesoscale, and macroscale cutting of steel. Ann CIRP 55(1):97–102
Monaghan J, Brazil D (1998) Modelling the flow processes of a particle reinforced metal matrix composite during machining. Compos A: Appl Sci Manuf 29(1–2):87–99
Nakayama K, Ogawa M (1978) Basic rules on the form of chip in metal cutting. Ann CIRP 27(1):17–20
Sun S, Brandt M, Dargusch MS (2009) Characteristics of cutting forces and chip formation in machining of titanium alloys. Int J Mach Tools Manuf 49(7–8):561–568
Aykut S, Bagci E, Kentli A, Yazlcloglu O (2007) Experimental observation of tool wear, cutting forces and chip morphology in face milling of cobalt based super-alloy with physical vapour deposition coated and uncoated tool. Mater Des 28(6):1880–1888
Hou ZB, Komanduri R (1997) Modeling of thermomechanical shear instability in machining. Int J Mech Sci 39(11):1273–1314
Li B (2011) Chip morphology of normalized steel when machining in different atmospheres with ceramic composite tool. Int J Ref Met Hard Mater 29(3):384–391
Gaitonde VN, Karnik SR, Figueira L, Davim JP (2009) Machinability investigations in hard turning of AISI D2 cold work tool steel with conventional and wiper ceramic inserts. Int J Ref Met Hard Mat 27(4):754–763
Author information
Authors and Affiliations
Corresponding author
Additional information
Highlights
▸Wear mechanism of tool and tribology characteristics of chip were revealed during cutting Fe-based amorphous alloy overlay.
▸A deformed shear band is due to severe plastic shear deformation in the chips of Fe-based amorphous alloy.
▸Surface roughness, tool failure, chip morphologies and the machined surface morphology of amorphous overlay at different cutting parameters were observed. And we found cutting speed is the main statistical significance on the surface roughness and surface damage.
Rights and permissions
About this article
Cite this article
Wang, M., Xu, B., Zhang, J. et al. Experimental observations on surface roughness, chip morphology, and tool wear behavior in machining Fe-based amorphous alloy overlay for remanufacture. Int J Adv Manuf Technol 67, 1537–1548 (2013). https://doi.org/10.1007/s00170-012-4588-z
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-012-4588-z