Effects of tool coating and tool wear on the surface and chip morphology in side milling of Ti2AlNb intermetallic alloys

doi:10.1007/s40436-024-00527-8

Advances in Manufacturing ›› 2025, Vol. 13 ›› Issue (1): 155-166.doi: 10.1007/s40436-024-00527-8

• • 上一篇

Effects of tool coating and tool wear on the surface and chip morphology in side milling of Ti₂AlNb intermetallic alloys

Xin Wang¹, Qing-Liao He¹, Biao Zhao¹, Wen-Feng Ding¹, Qi Liu², Dong-Dong Xu³

1. National Key Laboratory of Science and Technology on Helicopter Transmission, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, People's Republic of China;
2. Centre for Precision Manufacturing, University of Strathclyde, Glasgow, UK;
3. School of Mechanical Engineering, Tongji University, Shanghai 200092, People's Republic of China

收稿日期:2023-12-13 修回日期:2024-02-19 发布日期:2025-02-26
通讯作者: Biao ZHAO,E-mail:zhaobiao@nuaa.edu.cn E-mail:zhaobiao@nuaa.edu.cn
作者简介:Xin Wang is currently a Ph.D. candidate of Mechanical Engineering at Nanjing University of Aeronautics and Astronautics, P. R. China. His research interest is ultrasonic vibration-assisted cutting technology of difficult-tocut materials.
Qing-Liao He is currently a Master student of Mechanical Engineering at Nanjing University of Aeronautics and Astronautics, P. R. China. His research interest is ultrasonic vibrationassisted cutting technology of difficult-to-cut materials.
Biao Zhao is currently an Associate Professor of Mechanical Engineering and Master Supervisor at Nanjing University of Aeronautics and Astronautics, P. R. China. His research interests include high-efficiency and precision grinding technology and equipment, superhard abrasive tools, etc.
Wen-Feng Ding is currently a Professor of Mechanical Engineering and Doctoral Supervisor at Nanjing University of Aeronautics and Astronautics, P. R. China. His research interests include high-efficiency and precision grinding technology and equipment, machining process simulation and control technology, etc.
Qi Liu is currently an Assistant Professor at University of Strathclyde, Glasgow, UK. His main research interests include precision manufacturing.
Dong-Dong Xu is currently an Assistant Professor at Tongji University, Shanghai. His main research interests include advanced manufacturing technology for fatigue damage and repair of aviation components.
基金资助:
This work was financially supported by the National Natural Science Foundation of China (Grant Nos. 92160301, 92060203, 52175415, and 52205475), the Science Center for Gas Turbine Project (Grant Nos. P2022-AB-IV-002-001, P2023-B-IV-003-001), the Natural Science Foundation of Jiangsu Province (Grant No. BK20210295), the Superior Postdoctoral Project of Jiangsu Province (Grant No. 2022ZB215), the National Key Laboratory of Science and Technology on Helicopter Transmission (Nanjing University of Aeronautics and Astronautics) (Grant No. HTL-A-22G12), and the Postgraduate Research and Practice Innovation Program of Jiangsu Province (Grant No. KYCX22_0342).

Effects of tool coating and tool wear on the surface and chip morphology in side milling of Ti₂AlNb intermetallic alloys

Xin Wang¹, Qing-Liao He¹, Biao Zhao¹, Wen-Feng Ding¹, Qi Liu², Dong-Dong Xu³

1. National Key Laboratory of Science and Technology on Helicopter Transmission, Nanjing University of Aeronautics and Astronautics, Nanjing 210016, People's Republic of China;
2. Centre for Precision Manufacturing, University of Strathclyde, Glasgow, UK;
3. School of Mechanical Engineering, Tongji University, Shanghai 200092, People's Republic of China

Received:2023-12-13 Revised:2024-02-19 Published:2025-02-26
Contact: Biao ZHAO,E-mail:zhaobiao@nuaa.edu.cn E-mail:zhaobiao@nuaa.edu.cn
Supported by:
This work was financially supported by the National Natural Science Foundation of China (Grant Nos. 92160301, 92060203, 52175415, and 52205475), the Science Center for Gas Turbine Project (Grant Nos. P2022-AB-IV-002-001, P2023-B-IV-003-001), the Natural Science Foundation of Jiangsu Province (Grant No. BK20210295), the Superior Postdoctoral Project of Jiangsu Province (Grant No. 2022ZB215), the National Key Laboratory of Science and Technology on Helicopter Transmission (Nanjing University of Aeronautics and Astronautics) (Grant No. HTL-A-22G12), and the Postgraduate Research and Practice Innovation Program of Jiangsu Province (Grant No. KYCX22_0342).

摘要/Abstract

摘要： Ti₂AlNb intermetallic alloys, which belong to the titanium aluminum (TiAl) family, are currently being extensively researched and promoted in the aerospace industry because of their exceptional properties, including low density, high-temperature strength, and excellent oxidation resistance. However, the excellent fracture toughness of the material leads to the formation of surface defects during machining, thereby affecting the quality of the machined surface. In this study, Ti₂AlNb intermetallic alloys were subjected to side-milling trials to investigate the influence of tool coating and tool wear on both the machined surface quality and chip morphology. Specifically, the tool life, machined surface roughness, surface morphology, surface defects, and chip morphology were investigated in detail. The results indicated that the tool coating provided a protective effect, resulting in a threefold increase in the service life of the coated end mill compared to that of the uncoated one. A coated end mill yields a superior machined surface topography, as evidenced by reduced roughness and a more consistent morphology. Tool wear has a significant effect on the morphology of machined surfaces. The occurrence of material debris and feed marks became increasingly severe as the tool wore off. The chip morphology was not significantly affected by the tool coating. However, tool wear results in severe tearing along the chip edge, obvious plastic flow on the non-free surface, and a distinct lamellar structure on the free surface.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00527-8

关键词: Ti₂AlNb intermetallic alloy, Tool coating, Tool wear, Surface morphology, Chip morphology

Abstract: Ti₂AlNb intermetallic alloys, which belong to the titanium aluminum (TiAl) family, are currently being extensively researched and promoted in the aerospace industry because of their exceptional properties, including low density, high-temperature strength, and excellent oxidation resistance. However, the excellent fracture toughness of the material leads to the formation of surface defects during machining, thereby affecting the quality of the machined surface. In this study, Ti₂AlNb intermetallic alloys were subjected to side-milling trials to investigate the influence of tool coating and tool wear on both the machined surface quality and chip morphology. Specifically, the tool life, machined surface roughness, surface morphology, surface defects, and chip morphology were investigated in detail. The results indicated that the tool coating provided a protective effect, resulting in a threefold increase in the service life of the coated end mill compared to that of the uncoated one. A coated end mill yields a superior machined surface topography, as evidenced by reduced roughness and a more consistent morphology. Tool wear has a significant effect on the morphology of machined surfaces. The occurrence of material debris and feed marks became increasingly severe as the tool wore off. The chip morphology was not significantly affected by the tool coating. However, tool wear results in severe tearing along the chip edge, obvious plastic flow on the non-free surface, and a distinct lamellar structure on the free surface.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-024-00527-8

Key words: Ti₂AlNb intermetallic alloy, Tool coating, Tool wear, Surface morphology, Chip morphology

Xin Wang, Qing-Liao He, Biao Zhao, Wen-Feng Ding, Qi Liu, Dong-Dong Xu. Effects of tool coating and tool wear on the surface and chip morphology in side milling of Ti₂AlNb intermetallic alloys[J]. Advances in Manufacturing, 2025, 13(1): 155-166.

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Effects of tool coating and tool wear on the surface and chip morphology in side milling of Ti₂AlNb intermetallic alloys

Effects of tool coating and tool wear on the surface and chip morphology in side milling of Ti₂AlNb intermetallic alloys

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