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A Study of Tool Wear in Turning of Pure Aluminum and Drilling of Cfrp/Ti Stacks

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A Study of Tool Wear in Turning of Pure Aluminum and Drilling of Cfrp/Ti Stacks A STUDY OF TOOL WEAR IN TURNING OF PURE ALUMINUM AND DRILLING OF CFRP/TI STACKS By Xin Wang A DISSERTATION Submitted to Michigan State University in partial fulfillment of the requirements for the degree of DOCTOR OF PHILOSOPHY Mechanical Engineering 2012 ABSTRACT A STUDY OF TOOL WEAR IN TURNING OF PURE ALUMINUM AND DRILLING OF CFRP/TI STACKS By Xin Wang Tool wear in turning of pure aluminum and drilling of carbon fiber reinforced plastics (CFRP)/titanium (Ti) stacks was investigated due to their importance in modern manufacturing. Although pure aluminum is a ductile metal while CFRP contains brittle carbon fibers, there exist also few important similarities which impact tool wear. For instance, neither work material contains inclusions harder than the tool material. Thus, in both cases, the abrasive wear mechanism, which comes from the hard inclusion abrading the tool surface, cannot explain the tool wear. Thus, selecting a tool material solely based on higher hardness does not always provide a longer tool life. This study presents a new explanation for tool wear with these work materials based on our experiments. Fine and coarse grain tungsten carbide-cobalt tools were used for turning commercially pure aluminum. Two types of tool wear were observed on both grades of tools. The first type of wear was due to carbide grain pullout from the surface by adhesion. The abrasion by the pull-out grains was the second type of wear observed. Larger flank wear was observed on the fine grain carbide than the coarse grain carbide despite the higher hardness of the fine grain carbide. The increase in tool wear was explained by the higher probability of a finer carbide grain being pulled out of the matrix compared to a coarser carbide grain. The evolution of Built up edge (BUE) in aluminum turning was studied. It was shown that the BUE decreased after the cobalt binder on the surface of the tool was removed by wear. The influence of oxidation in the formation of BUE is also discussed. In the CFRP/Ti stack drilling study, three types of experiments were carried out: CFRP- only drilling, titanium-only drilling and combined CFRP/Ti stack drilling. The tool wear were investigated on uncoated WC-Co drills, diamond coated drills, AlMgB14 (BAM) coated drills and nano-composite coated drills. There were two significant findings in the CFRP-only drilling study. First, edge rounding was found to be the main tool wear mode for all types of drills. A hypothesis was developed to explain the cause of edge rounding wear in CFRP machining. In metal machining, the wear on the cutting edge is normally prevented by a stagnation zone. However, the fracture-based chip formation in cutting CFRP prevented the formation of a stagnation zone. Rapid wear rounds off the cutting edge. Second, the tool wear measurements in the CFRP drilling experiment did not match the abrasive wear resistance of the drills. Instead, the results from tribo-meter tests correlated well with the tool wear in the CFRP drilling. Therefore, it is believed that tribo-meter testing can be used to rank suitable tool materials for CFRP drilling without carrying out extensive drilling experiments. In Ti-only drilling, edge chipping and coating flake off were the dominant wear types. The diamond coating, which is effective in drilling CFRP-only, flaked off due to Coefficient of Thermal Expansion (CTE) mismatch and graphitization. Finally, it was found that CFRP/Ti stack drilling was mainly a combination of the gradual wear in CFRP drilling and the coating flaking off and edge chipping in Ti drilling. Study of the individual work materials provided understanding of the combined wear mechanisms. This allows for future improvement of tools used in the machining of CFRP/Ti stack drilling. ACKNOWLEDGMENTS My first debt of gratitude must go to my advisor, Dr. Patrick Kwon. He patiently provided the vision, encouragement and advice necessary for me to proceed through the doctoral program and complete my dissertation. I also wish to thank my committee members, Dr. Liu, Dr. Feeny and Dr. Lai for their support, guidance and availability. Appreciation for financial assistance and general guidance during the course of my studies goes to Los Alamos National Laboratory and the Boeing Company. A special thanks to Mr. Lars at Franhoufer CCL USA and Dr. Kim at Washington State University for their generousness in making equipment available for use. I want to thank Dr. Tim, Kyunghee Park, Sun Li and Jorge Olortegui-Yume for their unflagging encouragement and their service as a role model to me as a junior member of academia. A special acknowledgement is due to my co-worker David Schrock for his enlightening advice and help in improving my scientific and writing skills. Furthermore, I am appreciative of my co-workers Trung Nguyen and Wang Mingang for assistance with conducting some of the experiments contained in this work. Thanks also to Sirisak Tooptong and Matt Lempke for stimulating discussion and general support as friends and co-workers. Most importantly, I wish to thank my parents, Wang Changsong and Wang Weiguang. Their love provided my inspiration and was my driving force. I owe them everything and wish I could show them just how much I love and appreciate them. iv Table of Contents LIST OF FIGURES ................................................................................................................... viii LIST OF TABLES ....................................................................................................................... xv KEY TO ABBREVIATIONS .................................................................................................... xvi Chapter 1. Introduction ................................................................................................................ 1 1.1. The motivation to study tool wear in the machining ....................................................... 1 1.2. The principle wear mechanisms ........................................................................................ 4 1.2.1. Adhesive wear .............................................................................................................. 4 1.2.2. Abrasive wear ............................................................................................................... 7 1.2.3. Diffusion wear .............................................................................................................. 9 1.2.4. Dissolution wear ..........................................................................................................11 1.2.5. Fatigue wear ............................................................................................................... 12 1.3. The tool wear phenomena in the machining .................................................................. 13 1.3.1. Flank wear .................................................................................................................. 13 1.3.2. Crater wear ................................................................................................................ 14 1.3.3. Notch wear ................................................................................................................. 15 1.3.4. Built up edge .............................................................................................................. 16 1.3.5. Thermal Crack ........................................................................................................... 17 Chapter 2. Tool wear in turning of pure aluminum ................................................................. 18 2.1. Introduction of aluminum machining ............................................................................ 18 2.1.1. Dry machining of aluminum ........................................................................................ 18 2.2. Literature survey on tool wear in aluminum machining .............................................. 19 2.3. Dry turning of commercially pure aluminum experiment setup ................................. 23 2.3.1. Cutting tool and work material ................................................................................ 23 2.3.2. Tool wear test ............................................................................................................. 24 2.4. Experiment results and analysis ..................................................................................... 25 2.4.1. Delamination of tool material in physical detach the BUE .................................... 25 2.4.2. Flank wear evolution ................................................................................................. 28 2.5. Determining the tool wear mechanism ........................................................................... 32 v 2.6. Micro-fracture on the tool nose ....................................................................................... 34 2.7. FEM simulation of the temperature in pure aluminum machining ............................ 35 2.8. Built up edge test .............................................................................................................. 37 2.8.1. BUE evolution on the coarse grade carbide inserts ................................................ 37 2.8.2. Chemical composition of the BUE ........................................................................... 38 2.9. Carbon contamination ..................................................................................................... 40 2.10. Summary of tool wear
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