Vol. 24 No. 1 2022 3 EDITORIAL COUNCIL EDITORIAL BOARD EDITOR-IN-CHIEF: Anatoliy A. Bataev, D.Sc. (Engineering), Professor, Rector, Novosibirsk State Technical University, Novosibirsk, Russian Federation DEPUTIES EDITOR-IN-CHIEF: Vladimir V. Ivancivsky, D.Sc. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Vadim Y. Skeeba, Ph.D. (Engineering), Associate Professor, Department of Industrial Machinery Design, Novosibirsk State Technical University, Novosibirsk, Russian Federation Editor of the English translation: Elena A. Lozhkina, Ph.D. (Engineering), Department of Material Science in Mechanical Engineering, Novosibirsk State Technical University, Novosibirsk, Russian Federation The journal is issued since 1999 Publication frequency – 4 numbers a year Data on the journal are published in «Ulrich's Periodical Directory» Journal “Obrabotka Metallov” (“Metal Working and Material Science”) has been Indexed in Clarivate Analytics Services. We sincerely happy to announce that Journal “Obrabotka Metallov” (“Metal Working and Material Science”), ISSN 1994-6309 / E-ISSN 2541-819X is selected for coverage in Clarivate Analytics (formerly Thomson Reuters) products and services started from July 10, 2017. Beginning with No. 1 (74) 2017, this publication will be indexed and abstracted in: Emerging Sources Citation Index. Journal “Obrabotka Metallov” (“Metal Working & Material Science”) has entered into an electronic licensing relationship with EBSCO Publishing, the world's leading aggregator of full text journals, magazines and eBooks. The full text of JOURNAL can be found in the EBSCOhost™ databases. Novosibirsk State Technical University, Prospekt K. Marksa, 20, Novosibirsk, 630073, Russia Tel.: +7 (383) 346-17-75 http://journals.nstu.ru/obrabotka_metallov E-mail: metal_working@mail.ru; metal_working@corp.nstu.ru
OBRABOTKAMETALLOV Vol. 24 No. 1 2022 4 EDITORIAL COUNCIL EDITORIAL COUNCIL CHAIRMAN: Nikolai V. Pustovoy, D.Sc. (Engineering), Professor, President, Novosibirsk State Technical University, Novosibirsk, Russian Federation MEMBERS: The Federative Republic of Brazil: Alberto Moreira Jorge Junior, Dr.-Ing., Full Professor; Federal University of São Carlos, São Carlos The Federal Republic of Germany: Moniko Greif, Dr.-Ing., Professor, Hochschule RheinMain University of Applied Sciences, Russelsheim Florian Nürnberger, Dr.-Ing., Chief Engineer and Head of the Department “Technology of Materials”, Leibniz Universität Hannover, Garbsen; Thomas Hassel, Dr.-Ing., Head of Underwater Technology Center Hanover, Leibniz Universität Hannover, Garbsen The Spain: Andrey L. Chuvilin, Ph.D. (Physics and Mathematics), Ikerbasque Research Professor, Head of Electron Microscopy Laboratory “CIC nanoGUNE”, San Sebastian The Republic of Belarus: Fyodor I. Panteleenko, D.Sc. (Engineering), Professor, First Vice-Rector, Corresponding Member of National Academy of Sciences of Belarus, Belarusian National Technical University, Minsk The Ukraine: Sergiy V. Kovalevskyy, D.Sc. (Engineering), Professor, Vice Rector for Research and Academic Affairs, Donbass State Engineering Academy, Kramatorsk The Russian Federation: Vladimir G. Atapin, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Victor P. Balkov, Deputy general director, Research and Development Tooling Institute “VNIIINSTRUMENT”, Moscow; Vladimir A. Bataev, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Vladimir G. Burov, D.Sc. (Engineering), Professor, Novosibirsk State Technical University, Novosibirsk; Aleksandr N. Gerasenko, Director, Scientifi c and Production company “Mashservispribor”, Novosibirsk; Sergey V. Kirsanov, D.Sc. (Engineering), Professor, National Research Tomsk Polytechnic University, Tomsk; Aleksandr N. Korotkov, D.Sc. (Engineering), Professor, Kuzbass State Technical University, Kemerovo; Evgeniy A. Kudryashov, D.Sc. (Engineering), Professor, Southwest State University, Kursk; Dmitry V. Lobanov, D.Sc. (Engineering), Associate Professor, I.N. Ulianov Chuvash State University, Cheboksary; Aleksey V. Makarov, D.Sc. (Engineering), Corresponding Member of RAS, Head of division, Head of laboratory (Laboratory of Mechanical Properties) M.N. Miheev Institute of Metal Physics, Russian Academy of Sciences (Ural Branch), Yekaterinburg; Aleksandr G. Ovcharenko, D.Sc. (Engineering), Professor, Biysk Technological Institute, Biysk; Yuriy N. Saraev, D.Sc. (Engineering), Professor, Institute of Strength Physics and Materials Science, Russian Academy of Sciences (Siberian Branch), Tomsk; Alexander S. Yanyushkin, D.Sc. (Engineering), Professor, I.N. Ulianov Chuvash State University, Cheboksary
Vol. 23 No. 2 2021 5 CONTENTS OBRABOTKAMETALLOV TECHNOLOGY Kuznetsov V.P., Makarov A.V., Skorobogatov A.S., Skorynina P.A., Luchko S.N., Sirosh V.A., Chekan N.M. Normal force infl uence on smoothing and hardening of steel 03Cr16Ni15Mo3Ti1 surface layer during dry diamond burnishing with spherical indenter............................................................................ 6 Gubin D.S., Kisel’A.G. Calculation of temperatures during fi nishing milling of a nickel based alloys.......... 23 EQUIPMENT. INSTRUMENTS Bratan S.M., Roshchupkin S.I., Chasovitina A.S., Gupta K. The effect of the relative vibrations of the abrasive tool and the workpiece on the probability of material removing during fi nishing grinding................. 33 MATERIAL SCIENCE OzolinA.V., Sokolov E.G. Effect of mechanical activation of tungsten powder on the structure and properties of the sintered Sn-Cu-Co-W material................................................................................................................. 48 Korobov Yu.S., Alwan H.L., Makarov A.V., Kukareko V.A., Sirosh V.A., Filippov M.A., Estemirova S. Kh. Comparative study of cavitation erosion resistance of austenitic steels with different levels of metastability................................................................................................................................................... 61 Vologzanina S.A., IgolkinA.F., PeregudovA.A., Baranov I.V., Martyushev N.V. Effect of the deformation degree at low temperatures on the phase transformations and properties of metastable austenitic steels.......... 73 Filippov A.V., Shamarin N.N., Moskvichev E.N., Novitskaya O.S., Knyazhev E.O., Denisova Yu.A., Leonov A.A., Denisov V.V. Investigation of the structural-phase state and mechanical properties of ZrCrN coatings obtained by plasma-assisted vacuum arc evaporation..................................................................... 87 EDITORIALMATERIALS Guidelines for Writing a Scientifi c Paper ............................................................................................................ 103 Abstract requirements ......................................................................................................................................... 107 Rules for authors ................................................................................................................................................. 111 FOUNDERS MATERIALS 119 CONTENTS
OBRABOTKAMETALLOV Vol. 24 No. 1 2022 TECHNOLOGY Calculation of temperatures during finishing milling of a nickel based alloys Dmitry Gubin a, Anton Kisel b, * Omsk State Technical University, 11 Prospekt Mira, Omsk, 644050, Russian Federation a https://orcid.org/0000-0003-1825-1310, gubin.89@list.ru, b https://orcid.org/0000-0002-8014-0550, kisel1988@mail.ru Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2022 vol. 24 no. 1 pp. 23–32 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2022-24.1-23-32 Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov ART I CLE I NFO Article history: Received: 30 December 2021 Revised: 10 January 2022 Accepted: 15 February 2022 Available online: 15 March 2022 Keywords: Theoretical calculation of temperatures Milling Nickel based alloys Cutting temperature Acknowledgements Research were conducted at core facility “Structure, mechanical and physical properties of materials”. ABSTRACT Introduction. One of the most important tasks in cutting metals and alloys is the control of the temperature factor, since temperature is one of the limitations in determining cutting conditions. This approach makes it possible to determine rational (in some cases, optimal) milling modes. Experimental methods for determining the temperature are labor-consuming, costly and not always available. The labor-consuming nature lies in the need for constant adjustment of experimental equipment due to changing cutting conditions, electrical insulation of the tool and workpiece, the appearance of parasitic electrical micro-voltage (if we are talking about temperature measurement methods with thermocouples), constant calibration of instruments and selection of thermal radiation coefficients (if we are talking about non-contact measurement methods). In this regard, there is a need for a theoretical determination of temperatures during milling with minimal use of experimental data. The purpose of the work: to develop a method for theoretical calculation of temperature during milling (cutting) of nickel-based heat-resistant materials on the example of 56% Ni -Cr-W Mo-Co-Al alloy (56% Ni, 0.1% C, 10% Cr, 6.5% W, 6% Al, 6.5% Mo, 0.6% Si, 13 % Co, 1% Fe). Research methodology. To determine theoretically the cutting temperatures, a mathematical model is formed that takes into account the mechanical and thermophysical properties of the material being processed and its change depending on the temperature variations during milling, the geometry of the cutting tool and the features of the schematization of the milling process. The experimental part of the study is carried out on a console milling machine KFPE-250 with a CNC system Mayak-610. The 56% Ni -Cr-W Mo-Co-Al material is processed with a Seco JS513050D2C.0Z3-NXT cutter with different speeds and feeds. The temperature is measured using a Fluke Ti400 thermal imager. Results and discussion. A theoretical model for calculating the temperature (for the group of 77% Ni - Cr - Ti - Al - B, 66% Ni - Cr - Mo - W - Ti - Al, 73% Ni-Cr-Mo-Nb-Ti-Al and 56% Ni -Cr-W Mo-Co-Al alloys) during milling of heat-resistant nickel-based alloys is developed, which makes it possible to predict the temperature value at the face and flank of the tool when changing cutting conditions (speed, feed, depth, cutting tool geometry), as well as the cutting temperature. An analysis of the experimental and theoretically predicted values of the cutting temperature showed a satisfactory agreement between the corresponding values. For citation: Gubin D.S., Kisel’ A.G. Calculation of temperatures during finishing milling of a nickel based alloys. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2022, vol. 24, no. 1, pp. 23–32. DOI: 10.17212/1994-63092022-24.1-23-32. (In Russian). ______ * Corresponding author Kisel’ Anton G., Ph.D. (Engineering), Associate Professor Omsk State Technical University 11 Prospekt Mira, 644050, Omsk, Russian Federation Tel.: +7 (999) 458-08-25, e-mail: kisel1988@mail.ru Introduction Nickel-based heat-resistant alloys are widely used in the space, aircraft and power industries to design parts with high mechanical stress and high operating temperature. The processing (milling, turning, etc.) of heat-resistant alloys is always accompanied by high cutting temperatures. This is caused by high values of mechanical characteristics (ultimate strength and actual ultimate strength), low coefficients of thermal conductivity and thermal diffusivity [1–4]. The study of temperature phenomena during cutting of materials is of interest, due to the fact that temperature can act as one of the limiting factors, so it is important to predict the temperature to optimize the cutting process and increase tool life [5, 6]. Thus, at high temperatures, increased tool wear (plastic deformation), loss of dimensional stability and rapid failure are observed [5, 7,
OBRABOTKAMETALLOV technology Vol. 24 No. 1 2022 8]. In this connection, temperature is associated with such a factor as wear intensity and is further used as a limiting factor in determining rational (or optimal) cutting modes [5] (Figure 1). Figure 1 shows that the minimum wear rate of the tool for 70% Ni-Cr-W-Mo-Ti-Al and 70% Ni-Cr-WMo-Ti-Al-Nb alloys is the same and corresponds to a temperature value of about 750 oС at a cutting speed of 25 m/min. Fig. 1. Dependence of the wear rate of the cutter and the cutting temperature on the type of workpiece and cutting speed [5] So there are recommendations [5, 9], according to which it is expedient to assign cutting modes, maintaining rational (optimal) temperature values. In the work of A. D. Makarov [5], it was proposed to take into account the effect of cutting temperature on cutting speed. He formulated the principle that with various combinations of cutting speed, feed and depth of cut, a constant temperature in the cutting zone (optimal temperature) can be found, corresponding to the minimum average wear rates. In a number of works [10-12], the cutting temperature was determined either experimentally (by the method of natural – artificial thermocouple), or theoretically [6, 13]. Temperature measurement by experimental methods in production conditions is inefficient and leads to great difficulties. These difficulties are primarily associated with setting up expensive equipment for constantly changing cutting conditions (for example, the material of the workpiece has changed, the geometry of the cutting tool has changed, etc.) and calibration of the received thermal EMF signals (for thermocouples). If temperature measurements are made by non-contact methods (thermal imagers), then in this case there is a need to calibrate constantly the device when changing the processed material and to produce constant focusing when the cutting tool moves. In addition, it is impossible to measure the temperature by non-contact method when milling using coolant, or when the cutting zone is closed by the processed material, or chips. In this connection, it is advisable to use programs (methods) that allow theoretically calculating (predicting) the temperature for a certain group of processed materials, taking into account the influence of changes in mechanical characteristics during the cutting process, without resorting to a large number of experiments. Thus, Ezel et al. [14] proposed a theoretical model for calculating the temperature for high-speed end milling of die steels based on the finite element method. Based on the experimental data, the coefficients of the model were obtained, which were included in the DEFORM-2D software. Thus, the numerical method was limited to a specific material and specific machining conditions, and accuracy was compromised by assuming that the yield strength of the material is independent of strain, strain rate, and temperature during the milling process.
OBRABOTKAMETALLOV Vol. 24 No. 1 2022 technology This paper is devoted to the development of a theoretical method for calculating the temperature during milling for a group of nickel-based alloys. To achieve this purpose, it is necessary to develop a mathematical model that takes into account the effect of strain, strain rate and temperature on the change in the yield strength during milling and to confirm the results of theoretical prediction of cutting temperature experimentally (by non-contact method of temperature measurement). As an example, theoretical and experimental studies will be carried out for the 56% Ni-Cr-W-Mo-Co-Al heat-resistant alloy obtained by vacuum remelting. Research technique The first thing to consider when calculating the cutting temperature is the mechanical and physical properties of the material. Secondly, it is necessary to take into account the geometry of the cutting tool (back rake angle g°, front clearance angle α°, side cutting edge angle j°, rake angle λ°), as well as the schematization of the milling process, namely the infeed depth e, take into account the number of simultaneously working teeth, ratio of milling width to cutter diameter. The geometry of the cutting tool was taken into account through the Peclet criterion, which determines the heat exchange between the material being processed, the environment, and the tool, and through the Peclet coefficient, which takes into account the rate of heat removal [15]: 1 60 1000 v a Pe = ⋅ ⋅ w, (1) 1 1 exp( tg ) 1 tg y Pe y Pe K Pe − − ⋅ j = + ⋅ j , (2) sin cos z a S = ⋅ j ⋅ λ, (3) cos arctg sin y g j = z − g , (4) where a is the thickness of the cut layer in mm, ν is the cutting speed in m/s, w is the thermal diffusivity m2/s (reference value), S z is the feed per tooth in mm/tooth, j is the actual cutting edge angle in degrees, λ is the rake angle of the cutting edge in degrees, g is the back rake angle in degrees, jy is the angle of inclination of the conditional shear plane in degrees, z is chip shrinkage. Thirdly, it is necessary to take into account the influence of temperature itself on the change in the mechanical properties of the material. High temperatures during the cutting process can lead to a significant change in the mechanical properties of metals and alloys. It is known [16–18] that in the process of cutting under the influence of high strain rates, thematerial being processed can be significantly hardened, and under the influence of temperature, it can be softened. For the study, a group of heat-resistant alloys was selected, which obeys the same softening law (Figure 2), and therefore, the change in the yield strength of the above alloys can be described by one generalizing equation, and it is permissible to choose any of it for research. Fig. 2. Change in the mechanical properties of nickel based alloys during static tensile tests [15, 16]
OBRABOTKAMETALLOV technology Vol. 24 No. 1 2022 Ta b l e 1 Mechanical characteristics and physical properties of heat-resistant alloys required for temperature calculation Material grade Ultimate strength su, MPa Percentage elongation %EL, % Thermalconductivity coefficient λ, W/m·K Volumetric heat capacity СV, kJ/ m3·K Thermal diffusivity coefficient w, m2/s Density ρ, kg/m3 56% Ni-Cr-W-Mo-Co-Al 1,050 17 10.53 4.39 2.858ˑ10-6 8,400 The 56% Ni-Cr-W-Mo-Co-Al heat-resistant alloy was chosen for the study. The physical and mechanical properties of this material are presented in Table 1 [17, 18] The calculations are based on the dependences of the change in the actual ultimate strength on temperature during high-temperature tensile tests of heat-resistant alloys (Figure 2), as well as information on the effect of strain and strain rate on the change in the yield strength of the selected alloys [19]. Based on these data, a constitutive equation was built to determine the yield strength, which is suitable for any alloy shown in Figure 2: 0 exp( ) p m p q b A K B T S ε τ ′ = ε − ∆ , (5) 1 3 3 ln(1 ) m z A − = + ε , (6) where 0 p b S τ is the ratio of the value of the actual ultimate strength at the test temperature to the value of the ultimate strength at room temperature, m p A ⋅ ε is the equation of the material to be hardened (simple loading), m is the strain hardening coefficient, Kε is an empirical constant characterizing the effect of strain rate on the yield strength, q B is an empirical constant characterizing the effect of temperature softening of the material, T ∆ ′ is the increment of the homological temperature. In the literature there are similar models of the change in the yield strength depending on the strain, strain rate and temperature, for example, the Johnson-Cook model [20] ( )(1 ln )(1 ) n p m A B C T s = + ⋅ ε + ⋅ ε − . (7) But both the defining equation (5) and the Johnson-Cook model (7) have drawbacks. For example, in both equations, temperature acts as an independent factor, i.e. one can change the temperature by simply heating the material. In order to take into account the dependence of the combined effect of temperature, strain and strain rate during milling, it is necessary to replace in the constitutive equation (5) the ratio of the actual ultimate strength at the test temperature to the value of the actual ultimate strength at room temperature on the ultimate resilience [15]: 0 p w b p dA S d τ = ε , (8) 0 0 u p w b A d S ε τ = ε ∫ . (9)
OBRABOTKAMETALLOV Vol. 24 No. 1 2022 technology Due to the fact that during milling the conditions are quasi-adiabatic (there is an exchange with the environment and the material being processed), the temperature can be determined as follows: 1 Pe w T K A A ∆ ′ = ⋅ ⋅ , (10) 1 b V melt S A C T = . (11) Now the defining equation will take the following form: 1 exp( ) m w p q w Pe A A K B A A K d ε = ε − ε. (12) After integrating equation (12), and then differentiating, the points were found at which the highest values of cutting strength on the face surface are achieved: 0 0 0 1 1 exp 1 1 p b b ï b m m m S S B A K S θ τ − τ + = − ε q Pe , (13) 0 0 1 1 1 1 1 m ï b ï q Pe b m S AK B A K S + τ θ ε ε = − . (14) To calculate the temperatures on the major flank of the tool, the same formulas were used, but with different values of the coefficients: 0 0 0 2 1 exp 1 1 p b b ç b m m m S S B A K S θ τ − τ + = − ε q Pe , (15) 0 0 1 1 2 1 1 m ï b ç q Pe b m S AK B A K S + τ θ ε ε = − . (16) Due to equations (10–12), dependences (13 and 15) are heat sources on the face and flank surfaces, respectively. Then, using the iteration method in the Excel software environment, the temperatures on the face and flank surfaces were calculated and graphs were plotted. Below are graphs of the theoretical calculation of temperatures on the face surface of the cutting blade (Figure 3) and on the flank surface of the cutting blade (Figure 4) on the example of milling 56% Ni-Cr-W-Mo-Co-Al alloy with a Seco JS513050D2C.0Z3NXT carbide cutter (diameter 5 mm, number of teeth 3, helix angle 46o, end cutting edge angle j = 90o, rake angle λ = 0o, actual back rake angle λ =8o) with the following milling modes: V = 15.7 m/min; S min = = 52 mm/min; Sz = 0.0175 mm/tooth; n = 1,000 rpm; t = 0.1 mm. These graphs help to analyze and control the temperature process during milling because temperature change is directly related to changes in milling (cutting) modes.
OBRABOTKAMETALLOV technology Vol. 24 No. 1 2022 Results and discussion Theoretical calculations of the cutting temperature have been confirmed by a number of experimental studies. The study of the cutting temperature was carried out on a console milling machine KFPE-250 with a CNC system Mayak-610 during symmetrical milling of the 56% Ni-Cr-W-Mo-Co-Al alloy with a Seco JS513050D2C.0Z3-NXT carbide cutter. The milling depth for all experiments was 0.1 mm. To measure the cutting temperature, a Fluke Ti400 thermal imager was used with an error in measuring the non-stationary temperature field of 5 %. Milling was carried out with different feeds and cutting speeds (table 2). The cutting temperature (Figure 5) was calculated based on the average temperatures on the face and flank surfaces according to the formula: ( ) average average face flank cut T c T h T c h ⋅ + ⋅ = + , (17) where average face T and average flank T are the average temperatures on the face and flank surfaces of the cutting blade, c and h are the coordinates of the face and flank surfaces of the cutting blade along which the temperature is distributed. Fig. 3. Temperature distribution over the face surface during milling of nickel based alloy 56% Ni-Cr-W-Mo-Co-Al – theoretical method Fig. 4. Temperature distribution over the flank surface during milling of nickel based alloy 56% Ni-Cr-W-Mo-Co-Al – theoretical method
OBRABOTKAMETALLOV Vol. 24 No. 1 2022 technology Ta b l e 2 Temperature measurement results and corresponding theoretical calculations for milling Experiment No. 1 2 3 4 5 6 7 Texp, °С 327 280 294 374 206 273 237 Tcalc, °С 342 276 316 349 216 264 231 V, m/min 15.7 15.7 15.7 22 7.9 22 15.7 Sz, mm/tooth 0.0175 0.0095 0.0135 0.0095 0.0055 0.0055 0.0015 Fig. 5. Dependence of the cutting temperature on the cutting speed and feed during milling of nickel based alloy 56% Ni-Cr-W-Mo-Co-Al Conclusion As a result of the research, it was found that the maximum temperature value during milling of 56% Ni-Cr-W-Mo-Co-Al alloy with cutting speed V = 15.7 m/min, milling depth = 0.1 mm and feed Sz = 0.0175 mm/tooth was achieved on the face surface and amounted to 730 oС, while on the flank surface of the tool the temperature reached 450 oС. The cutting temperature was 327 °C. Comparison of experimental studies of milling heat-resistant alloy 56% Ni-Cr-W-Mo-Co-Al, with a change in cutting conditions (changed feed per tooth and cutting speed) with theoretical data, gave a satisfactory result with a confidential interval of 5%. On the basis of experimental data, it can be concluded that this method makes it possible to calculate (predict) theoretically the temperatures on the face and flank surfaces of the cutting blade, as well as the cutting temperature, without labor-consuming and costly experimental studies. The same method can be extended to other grades of heat-resistant alloys (77% Ni-Cr-Ti-Al-B, 66% Ni-CrMo-W-Ti-Al, 73% Ni-Cr-Mo-Nb-Ti-Al), since there is only one defining equation for it. When calculating, it is only necessary to change the values of its physical and mechanical characteristics. In the future, this method of theoretical calculation of temperature can be used to determine the minimum (reasonable) wear rate of the cutting tool.
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