Experimental investigation and FEM analysis of chip morphology in the turning of ASTM F-75 CoCrMo alloy

Abstract

During the machining process, problems such as tool wear, high temperature, force distribu-tion, and surface quality deterioration must be fully understood. Control of these problems with experimental studies and numerical analyses is important in ensuring dimensional ac-curacy and surface integrity of the cutting tool, workpiece, and also the finished product. The aim of this study is to investigate the effects of machining parameters on chip morphology, residual stresses and tool wear in turning operations of ASTM-F75 CoCrMo alloy experi-mentally and by finite element method (FEM) simulation. The study was carried out at three different feed rates (0.1, 0.2, 0.3 mm/rev) and at a constant cutting speed of 80 m/min both experimentally on a CNC turning machine and with FEM simulation. From the obtained re-sults, the formation of cracks and adhesions on the surfaces of the chip were observed due to the increase of the feed rate. According to the orthogonal cutting model, chip height ratio (Gs) and tooth pitch (Pc) values of saw-tooth chips supported each other with measurements taken from both FEM images and experimental images. With the increase of the forward speed, the Gs ratio decreased, while the Pc increased. In addition, microscopic images obtained from the cutting tool also showed that the rate of crater wear gradually increased with increasing feed rate. As a result, it is seen that machining parameters have a significant effect on cutting tool and chip morphology in CoCrMo ASTM-F75 alloy turning.

Keywords

• ASTM-F75 CoCrMo Alloy
• Chip Morphology Modelling
• FEM
• Turning

References

1. REFERENCES
2. [1] Attanasio A, Ceretti E, Fiorentino A, Cappellini C. Investigation and FEM-based simulation of tool wear in turning operations with uncoated carbide tools. Wear 2010;269:344–350. [CrossRef]
3. [2] Attanasio A, Faini F, Outeiro JC. FEM simulation of tool wear in drilling. Procedia CIRP 2017;58:440–444. [CrossRef]
4. [3] Gao XJ, Li H, Liu Q, Zou P, Liu F. Simulation of stainless steel drilling mechanism based on deform-3D. Adv Mater Res 2010;160–162:1685–1690. [CrossRef]
5. [4] Parida AK, Maity K. FEM analysis and experimental investigation of force and chip formation on hot turning of Inconel 625. Def Technol 2019;15:853–860. [CrossRef]
6. [5] Tang L, Sun Y, Li B, Sehn J, Meng G. Wear performance and mechanisms of PCBN tool in dry hard turning of AISI D2 hardened steel. Tribol Int 2019;132:228–236. [CrossRef]
7. [6] Li A. A review of tool wear estimation using theoretical analysis and numerical simulation technologies. Int J of Refract Met Hard Mater 2012;35:143–151. [CrossRef]
8. [7] Calamaz M, Limido J, Nouari M, Espinosa C, Coupard D, Salaün M, et al. Toward a better understanding of tool wear effect through a comparison between experiments and SPH numerical modelling of machining hard materials. Int J of Refract Met Hard Mater 2009;27:595–604. [CrossRef]

9. [8] Kountanya R, Al-Zkeri I, Altan T. Effect of tool edge geometry and cutting conditions on experimental and simulated chip morphology in orthogonal hard turning of 100Cr6 steel. J Mater Process Technol 2009;209:5068–5076. [CrossRef]
10. [9] Nan X, Xie L, Zhao W. On the application of 3D finite element modeling for small-diameter hole drilling of AISI 1045 steel.Int J Adv Manuf Technol 2015;84:1927–1939. [CrossRef]
11. [10] Yaylacı M, Abanoz M, Yaylacı EU, Ölmez H, Sekban DM, Birinci A. Evaluation of the contact problem of functionally graded layer resting on rigid foundation pressed via rigid punch by analytical and numerical (FEM and MLP) methods. Arch App Mech 2022;92:1953–1971. [CrossRef]
12. [11] Adıyaman G, Birinci A, Öner E, Yaylacı MA. Receding contact problem between a functionally graded layer and two homogeneous quarter planes. Acta Mech 2016;227:1753–1766. [CrossRef]
13. [12] Zhang G, To S, Xiao G. The relation between chip morphology and tool wear in ultra-precision raster milling. Int J Mach Tools Manuf 2014;80–81:11–17. [CrossRef]
14. [13] Jagtap KA, Pawade RS. Some studies on chip formation mechanism in CNC turning of biocompatible Co-Cr-Mo alloy. Procedia Manuf 2018;20:283–289. [CrossRef]
15. [14] Parida AK, Maity K. Experimental investigation on tool life and chip morphology in hot machining of Monel-400. Eng Sci Technol Int J 2018;21:371–379. [CrossRef]
16. [15] Zhao W, Gong L, Ren F, Li L, Xu Q, Khan AM. Experimental study on chip deformation of Ti-6Al-4V titanium alloy in cryogenic cutting. Int J Adv Manuf Technol 2018;96:4021–4027. [CrossRef]
17. [16] Bolat Ç, Ergene B, Karakılınç U, Gökşenli A. Investigating on the machinability assessment of precision machining pumice reinforced AA7075 syntactic foam. J Mech Eng Sci 2021;236:1986– 1996. [CrossRef]
18. [17] Alina BP, Aurel M. Study about the chip formation in the turning process using the finite element analysis,. The 25th Edition of IManEE 2021 International Conference (IManEE 2021) Mater Sci Eng 2022;1235:012019. [CrossRef]
19. [18] Wakjira MW, Janaki RP. Analysis of turning chip morphology with various tool geometries using finite element modeling and simulation to optimize product sustainability. Adv Mech Eng
20. 2022;14:168781322211364. [CrossRef] [19] Okokpujie IP, Chima PC, Tartibu LK. Experimental and 3D-deform finite element analysis on tool wear during turning of Al-Si-Mg alloy. Lubricants 2022;10:341. [CrossRef]
21. [20] Guoi Z, Pang X, Yan Y, Gao K, Volinsky AA, Zhang TY. CoCrMo alloy for orthopedic implant application enhanced corrosion and tribocorrosion properties by nitrogen ion implantation. Appl Surf Sci 2015;347:23–34. [CrossRef]
22. [21] Henriques B, Bagheri A, Gasik M, Souza JCM, Carvalho O, Silva FS, et al. Mechanical properties of hot pressed CoCrMo alloy compacts for biomedical applications. Mater Design 2015;83:829– 834. [CrossRef]
23. [22] Nurulamin AKM, Jaafar IH, Patwarı AU, Zubaire WWD. Role of discrete nature of chip formation and natural vibrations of system components in chatter formation during metal cutting. IIUM Eng J 2010;11:124–138. [CrossRef]
24. [23] Rahman MA, Bhuiyan MS, Sharma S, Kamal MS, Imtiaz MMM, Alfaify A, et al. Influence of Feed Rate Response (FRR) on chip formation in micro and macro machining of AI alloy. Metals 2021;11:159. [CrossRef]
25. [24] Lee WB, Cheung CF, To S. A microplasticity analysis of micro-cutting force variation in ultra-precision diamond turning. J Manuf Sci Eng 2002;124:170–177. [CrossRef]
26. [25] Zhu Z, Guo K, Sun J, Li J, Liu Y, Chen L, et al. Evolution of 3D chip morphology and phase transformation in dry drilling Ti6Al4V alloys. J Manuf Process 2018;34:531–539. [CrossRef]
27. [26] M’Hamdi M, BenSalem S, Boujelbene M, Katundi D, Bayraktar E. Effect of cutting parameters on the chip formation in orthogonal cutting. AIP Conf Proc 2011;1315:1101–1106. [CrossRef]
28. [27] Li J, Tao Z, Cai X, An Q, Chen M. Experimental and finite element analysis of the formation mechanism of serrated chips of nickel-based superalloy Inconel 718. Int J Adv Manuf Tech 2020;107:4969–4982. [CrossRef]
29. [28] Singh BK, Roy H, Mondal B, Roy SS, Mandal N. Measurement of chip morphology and multi criteria optimization of turning parameters for machining of AISI 4340 steel using Y-ZTA cutting insert. Measurement 2019;142:181–194. [CrossRef]
30. [29] Bordin A, Bruschi S, Ghiotti A, Bariani PF. Analysis of tool wear in cryogenic machining of additive manufactured Ti6Al4V alloy. Wear 2015;328-329:89–99. [CrossRef]
31. [30] Alojali HM, Benyounis KY. Advances in Tool Wear in Turning Process. In: Hashmi, S, editor. Reference module in materials science and materials engineering. Amsterdam: Elsevier; 2015. [CrossRef]
32. [31] Balaji M, Venkata K, Mohan N, Murthy BSN. Optimization of drilling parameters for drilling of TI-6Al4V based on surface roughness, flank wear and drill vibration. Measurement 2018;114:332– 339. [CrossRef]
33. [32] Grzesik W, Niesłony P, Habrat W, Sieniawski J, Laskowski P. Investigation of tool wear in the turning of Inconel 718 superalloy in terms of process performance and productivity enhancement. Tribol Int 2018;118:337–346. [CrossRef]
34. [33] Tagiuri ZAM, Dao TM, Samuel AM, Songmene V. A numerical model for predicting the effect of tool nose radius on machining process performance during orthogonal cutting of AISI 1045 steel. Materials (Basel) 2022;15:3369. [CrossRef]