Serrated chip characteristics and formation mechanism in high-speed machining of selective laser melted Ti6Al4V alloys

Serrated chips,consisting of extremely uneven plastic deformation,are a prominent feature of high-speed machining of difficultto-machine materials.This paper focuses on the evolution of chip form,chip morphology features(chip free surface,tool-chip contact surface,and chip edge),and chip segment parameters in subsequent high-speed(vc=50 and 150 m min-1)machining of selective laser melted(SLMed)Ti6Al4V alloys,which are significantly different from conventional Ti6Al4V alloy in microstructure,mechanical properties and machinability.The effect of laser beam scanning schemes(0°,67.5°,and 90°),machined surfaces(top and front),and cutting speeds on serrated chip characteristics of SLMed Ti6Al4Valloys was investigated.Based on the Johnson-Cook constitutive model of SLMed Ti6Al4Valloys,an orthogonal cutting model was developed to better understand the effect of physical-mechanical properties on the shear localization,which dominates the formation mechanism of serrated chips in post-machining of SLMed Ti6Al4V alloy.The results showed that the critical cutting speed(CCS)for chip serration of SLMed Ti6Al4V alloy is lower than that for serrated chips of conventional Ti6Al4V alloy,and the serrated profile of SLMed Ti6Al4V chips was more regular and pronounced.Besides,due to anisotropic microstructure and mechanical properties of SLMed Ti6Al4Valloys,the serration degree of chips produced on the top surfaces of SLMed Ti6Al4Valloys is more prominent than that of chips generated on the front surfaces.In addition,because of the poor deformation coordination and high plastic flow stresses of needle-like martensiteα′,the plastic flow and grain distortion in the adiabatic shear band(ASB)of SLMed Ti6Al4V chips are significantly smaller than those in the ASB of conventional Ti6Al4V with equiaxed grains.

Damage Characteristics of the Logical Chip Module Due to Plasma Created by Hypervelocity Impacts

To researching the damage characteristics of typical logical chip modules in spacecraft due to plasma generated by hypervelocity impacts,we have established a triple Langmuir probe diagnostic system and a logical chips measurement system,which were used to diagnose plasma characteristic parameters and the logical chip module＇s logical state changes due to the plasma created by a 7075 aluminum projectile hypervelocity impact on the 2A12 aluminum target.Three sets of experiments were performed with the collision speeds of 2.85 km/s,3.1 km/s and2.20 km/s,at the same incident angles of 30 degrees and logical chip module＇s positions by using a two-stage light gas gun loading system,a plasma characteristic parameters diagnostic system and a logical chip module＇s logical state measurement system,respectively.Electron temperature and density were measured at given position and azimuth,and damage estimation was performed for the logical chip module by using the data acquisition system.Experimental results showed that temporary damage could be induced on logical chip modules in spacecraft by plasma generated by hypervelocity impacts under the given experimental conditions and the sensors＇ position and azimuth.

Hard rock tunnel boring machine penetration test as an indicator of chipping process efficiency

The transition from grinding to chipping can be observed in tunnel boring machine(TBM) penetration test data by plotting the penetration rate(distance/revolution) against the net cutter thrust(force per cutter) over the full range of penetration rates in the test.Correlating penetration test data to the geological and geomechanical characteristics of rock masses through which a penetration test is conducted provides the ability to reveal the efficiency of the chipping process in response to changing geological conditions.Penetration test data can also be used to identify stress-induced tunnel face instability.This research shows that the strength of the rock is an important parameter for controlling how much net cutter thrust is required to transition from grinding to chipping.It also shows that the geological characteristics of a rock will determine how efficient chipping occurs once it has begun.In particular,geological characteristics that lead to efficient fracture propagation,such as fabric and mica contents,will lead to efficient chipping.These findings will enable a better correlation between TBM performance and geological conditions for use in TBM design,as a basis for contractual payments where penetration rate dominates the excavation cycle and in further academic investigations into the TBM excavation process.