Materials Science Forum Vol. 758 (2013) pp 157-164 © (2013) Trans Tech Publications, Switzerland doi:10.4028/www.scientific.net/MSF.758.157 Effect of the Cutting Velocity and Heat Treatment on Turning Cutting Forces of an SMA Cu-Al-Be Alloys Francisco Valdenor Pereira da Silva1a, José Paulo Vogel2b, Rodinei Medeiros Gomes1c, Tadeu Antonio de Azevedo Melo1d, Anna Carla Araujo3e and Silvio de Barros2f 1 Department of Mechanical Engineering, UFPB, João Pessoa/PB 58059-900, Brazil Department of Mechanical Engineering, CEFET/RJ, Rio de janeiro/RJ 20271-110, Brazil 3 Department of Mechanical Engineering, COPPE/UFRJ, Rio de Janeiro/RJ 21941-972, Brazil 2 a [email protected], [email protected], [email protected], [email protected], [email protected], [email protected] d Keywords: Metal Cutting, Cutting Forces, Shape memory alloy, Cu-Al-Be Alloy Abstract. This work studies the effect of heat treatment and cutting velocities on machining cutting forces in turning of a Cu-11.8%Al-0.55%Be shape memory alloys. The heat treatment was performed to obtain samples with austenite and martensite microstructures. Cutting force was investigated using a 3-component dynamometer in several revolutions and data were analyzed using statistic tools. It was found that the resultant forces were higher in quenched alloy due to the presence of Shape Memory Effect. Chip formation occurred in a shorter time in the sample without the Shape Memory Effect. Introduction Shape memory alloys (SMAs) are materials that have a singular property to return to a predetermined shape under specific thermomechanical conditions. A SMA workpiece at a temperature below its final martensite transformation temperature has very low yield strength and can be deformed easily. However, when heated it undergoes a change in crystal structure to austenite phase. Additionally at certain temperature range the austenite phase can undergoes a stress-induced transformation to martensite phase [1,2], a phenomenon that is responsible for the SMA pseudoelasticity. As metal cutting involves high temperatures and mechanical stress, both effects, shape memory and pseudo-elasticity, can cause many difficulties to machining these materials. Some studies have been conducted in machinability of NiTi SMAs. It was found that the cutting parameters, such as cutting speed and feed rate must be higher than that recommended in the literature. This is evidenced in turning because of the poor chip breaking and the formation of burrs which is caused by the high ductility of these materials [3]. Among the SMAs, copper based systems, as CuAlNi and CuAlBe, have been widely explored for certain application due to their low cost and good properties [4-5]. Studies on the mechanical properties and energy dissipation capacity of Copper-based alloys have been conducted [6]. The aim of this study is to compare the cutting forces generated during turning of quenched and unquenched specimens of Cu-11.8%Al-0.55%Be alloys. The cutting forces were investigated for four different cutting speed conditions. Material Workpiece Casting The workpieces for experimental investigation were especially casted with dimensions for external turning in a regular lathe. Cu-11.8%Al-0.55%Be (wt%) alloy was casted in the permanent steel mold showed in Fig. 1a. The ingots obtained after this process are shown in Fig. 1b. All rights reserved. No part of contents of this paper may be reproduced or transmitted in any form or by any means without the written permission of TTP, www.ttp.net. (ID: 146.164.52.66, UFRJ, Brazil-16/04/13,19:37:50) 158 Functional and Structural Materials II (a) (b) Figure 1. Workpiece Casting: (a) Permanent Mold and (b) As-cast specimens. It is necessary to perform a heat treatment in order to obtain the shape memory effect, as Cu-AlBe alloys have no shape memory after casting. The six specimens obtained were then separated in two groups: one group, with three workpieces, was heat-treated and the other group was machined as casted. The transformation temperatures for the quenched alloy in free stress state are as follow: austenitic start, As = -28.84°C, austenitic finish, Af = -6.87°C, martensitic start, Ms = -33.63°C, and martensitic finish, Mf= -54.56°C. Experimental Setup for Cutting Force Measurements The two groups described (quenched and not quenched) were submitted to machining experiments. Before the tests, the specimens were lightly machined in order to have a regular surface and not to induce thermal effects. Since temperature is an important variable, in order not to achieve high temperatures, the surface taken has one short passes with 15 mm length. Figure 2a presents the surface as it stood before testing. (a) (b) Figure 2. Experimental Set-up: (a) Specimen used in the tests and (b) Dynamometer and Force Components Cutting forces were taken continuously by using a piezoelectric dynamometer KISTLER model 9257 BA with amplifier 5233A and data acquisition board NI/USB 6221. Acquisition rate of 1kHz was applied. The signal processing was developed using MATLAB. The components Fx and Fy can be seen in the scheme presented in Fig. 2b, Fz is oriented in cutting direction, normal to the plane shown in this Figure. Materials Science Forum Vol. 758 159 The cutting conditions are shown in Table 1 where Vc is the cutting speed, n the spindle speed, ap the depth of cut, D the external diameter and f the feed per revolution. The design of experiments considered two factors: one factor with two levels (with and without heat treatment) e the other factor, Vc is cutting speed with four levels, as shown in Table 2, so 8 different experiments were developed. Fourteen revolutions were taken as different replicates in order to consider the experimental variance. Table 1. Cutting Conditions Alloy Cu-11.8%Al-0.55%Be Vc (m/min) 4 levels n (rpm) 1600 ap (mm) 0.50 D (mm) 30 f (mm/rev) 0.109 Table 2. Design of Experiments Levels 135.72 140.74 145.77 Quenched Not quenched - Variable Vc (m/min) Heat Treatment 150.79 - Results and Discussions In Fig. 3 it is shown the complete signals taken (14 revolutions) with Vc=150.79 m/min in a quenched workpiece (Fig. 3a) and no quenched workpiece (Fig. 3b). It was subtracted the effects of noise, through programmable logic suitable for both specimens. Experimental Forces in experiment Alloy: Cu-11,8%Al-0,55%Be quenched 300 Fz Fy 250 Fx Forces (N) 200 150 100 50 0 0 0.5 1 1.5 2 Time (s) (a) 2.5 3 3.5 4 160 Functional and Structural Materials II Experimental Forces in experiment Alloy: Cu-11,8%Al-0,55%Be No quenched 250 Fz Fy 200 Fx Forces (N) 150 100 50 0 -50 0 0.5 1 1.5 2 Time (s) 2.5 3 3.5 4 (b) Figure 3. Forces Results from experiments using Vc=150 m/min: : (a) Quenched Workpiece and (b) No-quenched Workpiece. Resultant force was calculated for all tests and 10 revolutions were analyzed to calculate the maximum resultant force for each revolution, the average resultant for on each revolution, and the peak-to-peak value. The results are shown graphically in Fig. 4 for the samples unquenched and quenched, for all cutting speed levels. Numerically, their values are shown in Table 3. Table 3. Resultant force by rotating piece: maximum, average and peak to peak to Cu-11.8%Al0.55%Be alloy – quenched and no quenched. Resultant Force [N] – Cu-11.8%Al-0.55%Be Alloy Maximum Average Peak-to-Peak Vc (m/min) No-Quenched Quenched No-Quenched Quenched No-Quenched Quenched 135 140 145 150 343.06 312.68 316.49 284.93 370.81 339.21 335.45 325.49 314.33 284.70 288.99 253.27 339.34 307.60 303.02 267.48 74.41 66.66 67.30 70.65 64.14 65.24 72.74 113.15 Materials Science Forum Vol. 758 (a) (b) 161 162 Functional and Structural Materials II (c) (d) Figure 4. (a), (b), (c) and (d) – Results for quenched and no quenched in 10 workpiece revolutions Materials Science Forum Vol. 758 163 Even with the ease of induction of martensite, to the case of the quenched sample, the forces obtained during its machining started at room temperature were higher than those of sample not quenched. Generally the resultant forces were greater for the quenched specimen than for the not quenched one. ANOVA analysis with two factors was applied to all results: quenched, No quenched and the four levels of cutting velocity in the three output results (Fmax, Fmean and Fpeak-to-peak). Fig. 5 presents the effect of cutting velocity for quenched tests (in left side) and without heat treatment (in right side). Vertical bars represent 95% interval of confidence, F-test(9, 170, 51)= 13,332 corresponding to p=0,00000. It is well known that cutting velocity enhance the cutting temperature. The forces decrease with the increase of cutting velocity. Peak-to-peak forces increase only in quenched in higher cutting velocity that can be related to phase change. Figure 5. Effect of Cutting Velocity in Quenched (+1) and No Quenched (-1) Tests using 95% C.I. and F(9, 170, 51)=13,332 corresponding to p=0,00000. Fig. 6 presents the effect of Heat Treatment (Quenched =1 and No Quenched =-1) on Maximum and Average Resultant Forces using all cutting velocities. The interval of confidence was 95% C.I. and F-test with (3, 70) results 264,23 corresponding to p=0,00000. It confirms that the heat treatment increases both: maximum force and mean force. 164 Functional and Structural Materials II Figure 6. Effect of Heat Treatment (Quenched =1 and No Quenched =-1) on Maximum and Average Resultant Forces using 95% C.I. and F(3, 70)= 264,23 corresponding to p=0,00000. Conclusions In this paper the cutting forces generated during turning of quenched and unquenched specimens of Cu-11.8%Al-0.55%Be alloys were investigated. Four different cutting speed levels were used to study these forces. The resultant forces obtained during machining of quenched samples were higher than those of unquenched alloy. This fact can be explained by the presence of Shape Memory Effect. Acknowledgements The authors acknowledge the technicians Jackson da Silva Farias Brito and Ieverton Caiandre Andrade for his contributions to the development of this work and the “Coordenação de Aperfeiçoamento de Pessoal de Nível Superior-CAPES”. References [1] K. Otsuka and C. M. Wayman. Shape Memory Materials: Cambridge University Press. (1998), pp. 284. [2] D.C. Lagoudas. Shape Memory Alloys - Modeling and Engineering Applications. TX - USA. (2008), pp. 435. [3] K. Weinert and V. Petzoldt: Materials Science & Engineering A Vol. 378 (2004), pp. 180-184. [4] S.M. Chentouf, M. Bouabdallah H. Cheniti, A. Eberhardt, E. Patoor and A. Sari: Materials Characterization Vol. 61 (2010), pp.1187-1193. [5] S. Montecinos, A. Cuniberti and M.L. Castro: Intermetallics Vol.18 n.1 (2010), pp.36-41. [6] J. Sepúlveda, R. Boroschek, R. Herrera, O. Moroni AND M. Sarrazin: Journal of Constructional Steel Research vol. 64 n.4 (2008), pp.429-435.
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