Date of Award

2014

Degree Type

Thesis

Degree Name

M.A.Sc.

Department

Mechanical, Automotive, and Materials Engineering

First Advisor

Alpas, Ahmet T.

Keywords

Applied sciences, Chip formation mecahnism, In-situ machining, Instability criterion, Orthogonal cutting, Ti-6al-4v cryogenic cooling, Tool wear

Rights

CC BY-NC-ND 4.0

Abstract

Dry and liquid nitrogen pre-cooled Ti-6Al-4V samples were machined at a cutting speed of 43.2 m/min and at low (0.1 mm/rev) to high (0.4 mm/rev) feed rates for understanding the effects of temperature and strain rate on chip microstructures. During cryogenic machining, it was observed that between feed rates of 0.10 and 0.30 mm/rev, a 25% pressure reduction on tool occurred. Smaller number of chips and low tool/chip contact time and temperature were observed (compared to dry machining under ambient conditions). An in-situ set-up that consisted of a microscope and a lathe was constructed and helped to propose a novel serrated chip formation mechanism when microstructures (strain localization) and surface roughness were considered. Dimpled fracture surfaces observed in high-speed-machined chips were formed due to stable crack propagation that was also recorded during in-situ machining. An instability criterion was developed that showed easier strain localization within the 0.10-0.30mm/rev feed rate range.

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