Hostname: page-component-78c5997874-8bhkd Total loading time: 0 Render date: 2024-11-03T05:27:41.478Z Has data issue: false hasContentIssue false
  • English
  • Français

Peripheral milling-induced residual stress and its effect on tensile–tensile fatigue life of aeronautic titanium alloy Ti–6Al–4V

Published online by Cambridge University Press:  14 March 2019

Dong Yang Open the ORCID record for Dong Yang [Opens in a new window] ,
Xiao Xiao ,
Yulei Liu  and
Jing Sun
Dong Yang*
Affiliation:
Department of Mechanical Engineering, Anhui University, Hefei, China
Xiao Xiao
Affiliation:
Hefei Science and Technology College, Hefei, China
Yulei Liu
Affiliation:
Department of Mechanical Engineering, Anhui University, Hefei, China
Jing Sun
Affiliation:
Hefei Science and Technology College, Hefei, China
*
*[email protected]
Get access Rights & Permissions [Opens in a new window]

Abstract

The special application environment puts forward the higher requirement of reliability of parts made from titanium alloy Ti–6Al–4V, which is closely related to the machining-induced residual stress. For the fact of the non-linear distribution of residual stress beneath the machined surface, distribution of peripheral milling-induced residual stress and its effect on fatigue performance of titanium alloy Ti–6Al–4V are still confusing. In the present study, residual stress profile induced by peripheral milling of Ti–6Al–4V is first studied. And then, energy criteria are proposed to characterise the whole state of the residual stress field. Finally, the effects of residual stress profile and surface energy on tensile–tensile fatigue performance of titanium alloy Ti–6Al–4V are discussed. The conclusions were drawn that the variation trend of surface residual stress (σr,Sur), maximum compressive residual stress (σC,ax), location (hr0) and response depth (hry) of residual stress profile with cutting parameters showed a similar pattern for both measure directions those parallel (σ1) and perpendicular (σ3) to the cutting direction. Cutting speed and feed rate have a main effect on surface residual stress, and the depth of cut has little effect on all the four key factors of residual stress profile. With the increase of cutting speed and feed rate, machining-induced surface energy tends to become larger. But increasing the depth of cut caused the strain energy stored in unit time to decrease. Furthermore, the effect of depth of cut on surface energy was weakened when the value of cutting depth becomes larger. Both the surface compressive residual stress and the maximum compressive residual stress are beneficial for prolonging the fatigue life, while large value of machining-induced surface energy leads to a decrease of fatigue life. Analysis of variance result shows that maximum residual compressive stress has a greater impact on fatigue life than other residual stress factors.

Keywords

Peripheral millingResidual stressSurface energyFatigue lifeTitanium alloy Ti–6Al–4V
Type
Research Article
Information
The Aeronautical Journal , Volume 123 , Issue 1260 , February 2019 , pp. 212 - 229
Check for updates
Copyright
© Royal Aeronautical Society 2019 

Access options

Get access to the full version of this content by using one of the access options below. (Log in options will check for institutional or personal access. Content may require purchase if you do not have access.)

References

1. Xiong, R. and Wu, H. Study on cutting mechanism of Ti6Al4V in ultra-precision machining, Int J Advanced Manufacturing Technology, 2016, 86, (5–8), pp 1–7.Google Scholar
2. Zhang, G., Liu, J., Liu, Y. and Yue, Z. Effect of roughness on surface stress concentration factor and fatigue life, J Mech Strength, 2010, 32, (1), pp 023.Google Scholar
3. Javidi, A., Rieger, U. and Eichlseder, W. The effect of machining on the surface integrity and fatigue life, Int J of fatigue, 2008, 30, (10–11), pp 2050–2055.Google Scholar
4. Sharman, A.R.C., Aspinwall, D.K., Dewes, R.C., Clifton, D. and Bowen, P. The effects of machined workpiece surface integrity on the fatigue life of γ-titanium aluminide, Int J Machine Tools and Manufacture, 2001, 41, (11), pp 1681–1685.Google Scholar
5. Liu, G.L., Huang, C.Z., Zou, B. and Liu, Z.Q. Surface integrity and fatigue performance of 17-4PH stainless steel after cutting operations, Surface and Coatings Technology, 2016, 307, pp 182–189.Google Scholar
6. Li, Y.J., Xuan, F.Z., Wang, Z.D. and Tu, S.T. Effects of residual stresses on the high cycle fatigue behavior of Ti–6Al–4V, ASME 2010 Pressure Vessels and Piping Division/K-PVP Conference, American Society of Mechanical Engineers, 2010, pp 397–401.Google Scholar
7. Smith, S., Melkote, S.N., Lara-Curzio, E., Watkins, T.R., Allard, L. and Riester, L. Effect of surface integrity of hard turned AISI 52100 steel on fatigue performance, Materials Science and Engineering: A, 2007, 459, (1–2), pp 337–346.Google Scholar
8. Farrahi, G.H., Lebrijn, J.L. and Couratin, D. Effect of shot peening on residual stress and fatigue life of a spring steel, Fatigue and Fracture of Engineering Materials and Structures, 1995, 18, (2), pp 211–220.Google Scholar
9. Guo, Y.B. and Yen, D.W. Hard turning versus grinding – the effect of process-induced residual stress on rolling contact, Wear, 2004, 256, (3–4), pp 393–399.Google Scholar
10. Guo, Y.B. and Barkey, M.E. Modeling of rolling contact fatigue for hard machined components with process-induced residual stress, Int J of fatigue, 2004, 26, (6), pp 605–613.Google Scholar
11. Sun, J. and Guo, Y.B. A comprehensive experimental study on surface integrity by end milling Ti–6Al–4V, J Materials Processing Technology, 2009, 209, (8), pp 4036–4042.Google Scholar
12. Sridhar, B.R., Devananda, G., Ramachandra, K. and Bhat, R. Effect of machining parameters and heat treatment on the residual stress distribution in titanium alloy IMI-834, J Materials Processing Technology, 2003, 139, (1–3), pp 628–634.Google Scholar
13. Guerville, L., Vigneau, J., Dudzinski, D., Molinari, A. and Schulz, H. Influence of machining conditions on residual stresses, Metal Cutting and High-Speed Machining, Kluwer Academic Plenum Publishers, New York, US, 2002, pp 201–210.Google Scholar
14. Mantle, A.L. and Aspinwall, D.K. Surface integrity of a high speed milled gamma titanium aluminide, J Materials Processing Technology, 2001, 118, (1–3), pp 143–150.Google Scholar
15. Yang, D., Liu, Z.Q., Ren, X.P. and Zhuang, P. Hybrid modeling with finite element and statistical methods for residual stress prediction in peripheral milling of titanium alloy Ti–6Al–4V, Int J of Mechanical Sciences, 2016, 108, pp 29–38.Google Scholar
16. Vosough, M., Kalhori, V., Liu, P. and Svenningsson, I. Influence of High Pressure Water-Jet Assisted Turning on Surface Residual Stresses on Ti–6Al–4V Alloy by Measurement and Finite Element Simulation, In Surface Engineering, Proceedings of the 3rd International Surface Engineering Congress, 2005, pp 107–113.Google Scholar
17. Ulutan, D. Predictive Modeling and Multi-objective Optimization of Machining-Induced Residual Stresses: Investigation of Machining Parameter Effects, Dissertations & Theses, Gradworks, 2013.Google Scholar
18. Ulutan, D., Arisoy, Y.M., Özel, T. and Mears, L. Empirical modeling of residual stress profile in machining nickel-based super alloys using the sinusoidal decay function, Procedia CIRP, 2014, 13, pp 365–370.Google Scholar
19. Srikanth, R., Kosmac, T., Bona, A.D., Yin, L. and Zhang, Y. Effects of cementation surface modifications on fracture resistance of zirconia, Dental Materials, 2015, 31, (4), pp 435–442.Google Scholar
20. Westergaard, H.M. Bearing pressures and cracks, Spie Milestone Series Ms, 1997, 137, pp 18–22.Google Scholar
21. Wang, X.G., Crupi, V., Guo, X.L. and Zhao, Y.G. Quantitative thermographic methodology for fatigue assessment and stress measurement, Int J of fatigue, 2010, 32, (12), pp 1970–1976.Google Scholar
22. Feltner, C.E. and Morrow, J.D. Microplastic strain hysteresis energy as a criterion for fatigue fracture, J of Basic Engineering, 1961, 83, (1), pp 15–22.Google Scholar
23. Morrow, J.D. Cyclic Plastic Strain Energy and Fatigue of Metals. Internal Friction, Damping, and Cyclic Plasticity, ASTM Int, 1965.Google Scholar
24. Macek, W., Łagoda, T. and Mucha, N. Energy-based fatigue failure characteristics of materials under random bending loading in elastic-plastic range, Fatigue & Fracture of Engineering Materials & Structures , 2018, 41, (2), pp 249–259.Google Scholar