Experimental investigation of the effects of cutting parameters on machinability of ECAP-processed ultrafine-grained copper using tungsten carbide cutting tools

Authors

1 School of Mechanical Engineering, College of Engineering, University of Tehran, P.O. Box 11155/4563, Tehran, Iran

2 Department of Mechanical Engineering, School of Engineering Technology and Industrial Trades, University of Doha for Science and Technology, Doha, Qatar

Abstract

The production of nanostructure materials or ultrafine grain (UFG) has been noticed by most of research society due to high strength, wear resistance, formability and high plastic strain rate. These features result from microstructure materials (100-300 nm) and unique defect (grain boundary-dislocation) make these material ideal for medical implant and structured components of aerospace and energy systems. The ways of producing UFG for these advanced engineering projects have not been considered yet. Due to the fact that nanostructured materials can show a good mechanical strength, researchers are using different ways to change pure copper into nanostructure one. One of these methods is applying process in equal channel angular pressing (ECAP), which coarse grain copper changed to nanostructure one. In this study, machinability of UFG as well as coarse grain (CG) copper is really considered in turning. To evaluate the machinability, cutting force, tool wear, chip morphology and surface roughness have been studied. Experimental results confirmed that UFG copper can be machined more efficiently than CG copper. In other words, the amount of BUE is reduced during turning ECAP copper due to the hardening of the pure sample. In comparison to CG copper, cutting force and surface roughness for UFG copper were less. As a result, machining performance can be improved partly by cold-work applying ECAP process.

Keywords


[1] Lowe TC (2006) Metals and alloys nanostructured by severe plastic deformation: commercialization pathways. JOM, 58(4):28-32.
[2] Valiev RZ (1997) Structure and mechanical properties of ultrafine-grained metals. Materials Science and Engineering: A 234:59-66.
[3] Faraji G, Babaei A, Mosavi Mashhadi M, Abrinia K (2012) Parallel tubular channel angular pressing (PTCAP) as a new severe plastic deformation method for cylindrical tubes. Materials Letters 77:82-85.
[4] Bhattacharyya A (1984) Metal cutting: theory and practice. Jamini Kanta Sen of Central Book Publishers.
[5] Morehead M, Huang Y, Hartwig KT (2007) Machinability of ultrafine-grained copper using tungsten carbide and polycrystalline diamond tools. International Journal of Machine Tools and Manufacture 47(2):286-293 .
[6] Morehead M, Huang Y (2005) Machinability research and workpiece microstructure characterization in turning of ultrafine grained copper. ASME International Mechanical Engineering Congress and Exposition.
[7] Astakhov VP (2010) Geometry of single-point turning tools and drills: fundamentals and practical applications. Springer-Verlag London.
[8] Mills B (2012) Machinability of engineering materials. Springer-Verlag London.
[9] Rajemi M, Mativenga P, Aramcharoen A (2010) Sustainable machining: selection of optimum turning conditions based on minimum energy considerations. Journal of Cleaner Production 18(10-11):1059-1065.
[10] Tawakoli T, Hadad MJ, Sadeghi MH, Daneshi A, Stöckert S, Rasifard A (2009) An experimental investigation of the effects of workpiece and grinding parameters on minimum quantity lubrication-MQL
grinding. International Journal of Machine Tools & Manufacture 49:924-932.
[11] Huang Y (2002) Predictive modeling of tool wear rate with application to CBN hard turning. Georgia Institute of Technology.
[12] Astakhov VP (2004) The assessment of cutting tool wear. International Journal of Machine Tools and Manufacture 44(6):637-647.
[13] Sivaraman V, Sankaran S, Vijayaraghavan L (2012) The effect of cutting parameters on cutting force during turning multiphase microalloyed steel. Procedia CIRP 4: 157-160.
[14] Shaw M, Vyas A (1993) Chip formation in the machining of hardened steel. CIRP annals, 42(1):29-33.
[15] Azushima A, Aoki K (2002) Properties of ultrafine-grained steel by repeated shear deformation of side extrusion process. Materials Science and Engineering: A 337(1-2):45-49.
[16] Kuyucak S, Sahoo M (1996) A review of the machinability of copper-base alloys. Canadian Metallurgical Quarterly 35(1):1-15.