Chip formation, cutting forces, and tool wear in turning of Zr-based bulk metallic glass

Mustafa Bakkal; Albert J. Shih; Ronald O. Scattergood

doi:10.1016/j.ijmachtools.2004.02.002

Chip formation, cutting forces, and tool wear in turning of Zr-based bulk metallic glass

Mustafa Bakkal, Albert J. Shih^*, Ronald O. Scattergood

^*Corresponding author for this work

Research output: Contribution to journal › Article › peer-review

160 Citations (Scopus)

Abstract

The chip light emission and morphology, cutting forces, surface roughness, and tool wear in turning of Zr-based bulk metallic glass (BMG) material are investigated. Machining results are compared with those of aluminum 6061-T6 and AISI 304 stainless steel under the same cutting conditions. This study demonstrates that the high cutting speeds and tools with low thermal conductivity and rake angle activate the light emission and chip oxidation in BMG machining. For the BMG chip without light emission, serrated chip formation with adiabatic shear band and void formation is observed. The cutting force analysis further correlates the chip oxidation and specific cutting energy and shows the significant reduction of cutting forces for machining BMG at high cutting speeds. The machined surface of BMG has better surface roughness than that of the other two work materials. Some tool wear features, including the welding of chip to the tool tip and chipping of the polycrystalline cubic boron nitride (PCBN) tool edge, are reported for turning of BMG. This study concludes that BMG can be machined with good surface roughness using conventional cutting tools.

Original language	English
Pages (from-to)	915-925
Number of pages	11
Journal	International Journal of Machine Tools and Manufacture
Volume	44
Issue number	9
DOIs	https://doi.org/10.1016/j.ijmachtools.2004.02.002
Publication status	Published - Jul 2004
Externally published	Yes

Funding

The tooling and technical support from Parag Hegde of Kennametal are greatly appreciated. A portion of this research was sponsored by the Heavy Vehicle Propulsion Systems Materials Program, Office of Transportation Technologies, US Department of Energy and by the Assistant Secretary for Energy Efficiency and Renewable Energy, Office of Transportation Technologies, as part of the High Temperature Materials Laboratory User Program, Oak Ridge National Laboratory, managed by UT-Battelle, LLC for the US Department of Energy under contract number DE-AC05-00OR22725.

Funders	Funder number
Office of Transportation Technologies
U.S. Department of Energy
Office of Energy Efficiency and Renewable Energy
Oak Ridge National Laboratory
UT-Battelle	DE-AC05-00OR22725

Keywords

Bulk metallic glass
Cutting forces
Machining
Surface roughness
Tool wear

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

Access to Document

10.1016/j.ijmachtools.2004.02.002

Cite this

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title = "Chip formation, cutting forces, and tool wear in turning of Zr-based bulk metallic glass",

abstract = "The chip light emission and morphology, cutting forces, surface roughness, and tool wear in turning of Zr-based bulk metallic glass (BMG) material are investigated. Machining results are compared with those of aluminum 6061-T6 and AISI 304 stainless steel under the same cutting conditions. This study demonstrates that the high cutting speeds and tools with low thermal conductivity and rake angle activate the light emission and chip oxidation in BMG machining. For the BMG chip without light emission, serrated chip formation with adiabatic shear band and void formation is observed. The cutting force analysis further correlates the chip oxidation and specific cutting energy and shows the significant reduction of cutting forces for machining BMG at high cutting speeds. The machined surface of BMG has better surface roughness than that of the other two work materials. Some tool wear features, including the welding of chip to the tool tip and chipping of the polycrystalline cubic boron nitride (PCBN) tool edge, are reported for turning of BMG. This study concludes that BMG can be machined with good surface roughness using conventional cutting tools.",

keywords = "Bulk metallic glass, Cutting forces, Machining, Surface roughness, Tool wear",

author = "Mustafa Bakkal and Shih, \{Albert J.\} and Scattergood, \{Ronald O.\}",

year = "2004",

month = jul,

doi = "10.1016/j.ijmachtools.2004.02.002",

language = "English",

volume = "44",

pages = "915--925",

journal = "International Journal of Machine Tools and Manufacture",

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}

TY - JOUR

T1 - Chip formation, cutting forces, and tool wear in turning of Zr-based bulk metallic glass

AU - Bakkal, Mustafa

AU - Shih, Albert J.

AU - Scattergood, Ronald O.

PY - 2004/7

Y1 - 2004/7

N2 - The chip light emission and morphology, cutting forces, surface roughness, and tool wear in turning of Zr-based bulk metallic glass (BMG) material are investigated. Machining results are compared with those of aluminum 6061-T6 and AISI 304 stainless steel under the same cutting conditions. This study demonstrates that the high cutting speeds and tools with low thermal conductivity and rake angle activate the light emission and chip oxidation in BMG machining. For the BMG chip without light emission, serrated chip formation with adiabatic shear band and void formation is observed. The cutting force analysis further correlates the chip oxidation and specific cutting energy and shows the significant reduction of cutting forces for machining BMG at high cutting speeds. The machined surface of BMG has better surface roughness than that of the other two work materials. Some tool wear features, including the welding of chip to the tool tip and chipping of the polycrystalline cubic boron nitride (PCBN) tool edge, are reported for turning of BMG. This study concludes that BMG can be machined with good surface roughness using conventional cutting tools.

AB - The chip light emission and morphology, cutting forces, surface roughness, and tool wear in turning of Zr-based bulk metallic glass (BMG) material are investigated. Machining results are compared with those of aluminum 6061-T6 and AISI 304 stainless steel under the same cutting conditions. This study demonstrates that the high cutting speeds and tools with low thermal conductivity and rake angle activate the light emission and chip oxidation in BMG machining. For the BMG chip without light emission, serrated chip formation with adiabatic shear band and void formation is observed. The cutting force analysis further correlates the chip oxidation and specific cutting energy and shows the significant reduction of cutting forces for machining BMG at high cutting speeds. The machined surface of BMG has better surface roughness than that of the other two work materials. Some tool wear features, including the welding of chip to the tool tip and chipping of the polycrystalline cubic boron nitride (PCBN) tool edge, are reported for turning of BMG. This study concludes that BMG can be machined with good surface roughness using conventional cutting tools.

KW - Bulk metallic glass

KW - Cutting forces

KW - Machining

KW - Surface roughness

KW - Tool wear

UR - https://www.scopus.com/pages/publications/2642523689

U2 - 10.1016/j.ijmachtools.2004.02.002

DO - 10.1016/j.ijmachtools.2004.02.002

M3 - Article

AN - SCOPUS:2642523689

SN - 0890-6955

VL - 44

SP - 915

EP - 925

JO - International Journal of Machine Tools and Manufacture

JF - International Journal of Machine Tools and Manufacture

IS - 9

ER -

Chip formation, cutting forces, and tool wear in turning of Zr-based bulk metallic glass

Abstract

Funding

Keywords

UN SDGs

Access to Document

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