journal article·2022-08-28

Surface characteristics study of Ti–6Al–4V alloy for biomedical applications using finite element modeling

Viveksheel Rajput, Mudimallana Goud, Narendra Mohan Suri, Sarbjit Singh, Ganga Ram Chaudhary

Journal of Materials Research· Volume 37· Issue 16
Publisher page

Abstract

The Ti–6Al–4V alloy, due to its low elastic modulus and outstanding biocompatibility, is extensively used in the field of biomedical. Nevertheless, their surface properties deteriorate with the conventional machining methods because of cutting forces, and residual stresses, and thus, non-conventional methods are employed. This paper investigates the surface characteristics study of Ti–6Al–4V alloy in terms of material removal rate (MRR), crater formation, and temperature distribution using finite element modeling (FEM) based novel multi-spark simulation with the electrochemical discharge phenomena. Subsequently, the predicted results are validated through machining and observed to be in consensus with the experimental results. The plots of temperature distributions are studied and inspected for evaluating the crater formation, crater depth, and MRR in Ti–6Al–4V alloy. The formation of the crater and the material removed indicates the possibility of retaining surface properties of the Ti–6Al–4V alloy with non-conventional electrochemical discharge phenomena. The machined surface is analyzed using FESEM to study the microstructural analysis.Graphical abstract
Source: expertdata · Quality: candidate unverified · Source record ↗

Research context

OpenAlex topics: Advanced Machining and Optimization Techniques · Advanced machining processes and optimization · Advanced Surface Polishing Techniques

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (44)

Show source-provided references
1. A. Kumar, V. Gupta, R.K. Prasad et al., Recent advances in processing of titanium alloys and titanium aluminides for space applications: a review. J. Mater. Res. 36, 689–716 (2021). https://doi.org/10.1557/s43578-021-00104-w10.1557/s43578-021-00104-w ↗
2. B.A. Begley, K. Markham, M. Mizak, Prediction of relative globularization rates in α + β titanium alloys as a function of initial crystal orientation. J. Mater. Res. 35, 1113–1120 (2020). https://doi.org/10.1557/jmr.2020.5410.1557/jmr.2020.54 ↗
3. H. Eskandari, H.R. Lashgari, S. Zangeneh, Microstructural characterization and mechanical properties of SLM-printed Ti–6Al–4V alloy: effect of build orientation. J. Mater. Res. (2022). https://doi.org/10.1557/s43578-021-00468-z10.1557/s43578-021-00468-z ↗
4. D. Banerjee, J.C. Williams, Perspectives on titanium science and technology. Acta Mater. 61, 844–879 (2013)10.1016/j.actamat.2012.10.043 ↗
5. S.P. Cooper, G.H. Whitley, Titanium in the power generation industry. Mater. Sci. Technol. 3, 91–96 (1987)10.1179/mst.1987.3.2.91 ↗
6. C. Leyens, M. Peters (eds.), Titanium and Titanium Alloys (Wiley, Weinheim, 2006)
7. S. Zhao, S.J. Li, S.G. Wang, W.T. Hou, Y. Li, L.C. Zhang, Y.L. Hao, R. Yang, R.D.K. Misra, L.E. Murr, Compressive and fatigue behavior of functionally graded Ti–6Al–4V meshes fabricated by electron beam melting. Acta Mater. 150, 1–15 (2018)10.1016/j.actamat.2018.02.060 ↗
8. G. Singh, T.R. Ablyaz, E.S. Shlykov, K.R. Muratov, A.S. Bhui, S.S. Sidhu, Enhancing corrosion and wear resistance of Ti–6Al–4V alloy using CNTs mixed electro-discharge process. Micromachines 11(9), 850 (2020). https://doi.org/10.3390/mi1109085010.3390/mi11090850 ↗
9. M.O. Bodunrin, J.A. Omotoyinbo, Development of low-cost titanium alloys: a chronicle of challenges and opportunities. Mater. Today Proc. (2020). https://doi.org/10.1016/j.matpr.2020.02.97810.1016/j.matpr.2020.02.978 ↗
10. S. Ganguli, S.G. Kapoor, Improving the performance of milling of titanium alloys using the atomization-based cutting fluid application system. J. Manuf. Process. 23, 29–36 (2016). https://doi.org/10.1016/j.jmapro.2016.05.011.Mmm10.1016/j.jmapro.2016.05.011.Mmm ↗
11. S. Carvalho, A. Horovistiz, J.P. Davim, Surface topography in machining Ti alloys for biomedical applications: correlative microscopy approach for qualitative and quantitative analysis. Int. J. Adv. Manuf. Technol. 114, 683–694 (2021). https://doi.org/10.1007/s00170-021-06824-x10.1007/s00170-021-06824-x ↗
12. A. Pramanik, Problems and solutions in machining of titanium alloys. Int. J. Adv. Manuf. Technol. 70, 919–928 (2014). https://doi.org/10.1007/s00170-013-5326-x10.1007/s00170-013-5326-x ↗
13. N.S. Weston, M. Jackson, FAST-forge of titanium alloy Swarf: a solid-state closed-loop recycling approach for aerospace machining waste. Metals 10, 296 (2020)10.3390/met10020296 ↗
14. R.S. Revuru, J.Z. Zhang, N.R. Posinasetti, T. Kidd, Optimization of titanium alloys turning operation in varied cutting fluid conditions with multiple machining performance characteristics. Int. J. Adv. Manuf. Technol. 95, 1451–1463 (2018)10.1007/s00170-017-1299-5 ↗
15. H.H. Su, P. Liu, Y.C. Fu, J.H. Xu, Tool life and surface integrity in high-speed milling of titanium alloy TA15 with PCD/PCBN tools. Chin. J. Aeronaut. 25(5), 784–790 (2012)10.1016/S1000-9361(11)60445-7 ↗
16. A. Pramanik, G. Littlefair, Machining of titanium alloy (Ti–6Al–4V)—theory to application. Mach. Sci. Technol. 19(1), 1–49 (2015). https://doi.org/10.1080/10910344.2014.99103110.1080/10910344.2014.991031 ↗
17. E.O. Ezugwu, Z.M. Wang, Titanium alloys and their machinability—a review. J. Mater. Process Technol. 68(3), 262–274 (1997)10.1016/S0924-0136(96)00030-1 ↗
18. H. Jing, M. Zhou, J. Yang, S. Yao, Stable and fast electrical discharge machining titanium alloy with MIMO adaptive control system. Procedia CIRP 68, 666–671 (2018)10.1016/j.procir.2017.12.151 ↗
19. G. Thangamani, M. Thangaraj, K. Moiduddin, S.H. Mian, H. Alkhalefah, U. Umer, Performance analysis of electrochemical micro machining of titanium (Ti–6Al–4V) alloy under different electrolytes concentrations. Metals 11(2), 247 (2021). https://doi.org/10.3390/met1102024710.3390/met11020247 ↗
20. A. Taherkhani, M.A. Ilani, F. Ebrahimi et al., Investigation of surface quality in cost of goods manufactured (COGM) method of μ-Al2O3 powder-mixed-EDM process on machining of Ti–6Al–4V. Int. J. Adv. Manuf. Technol. 116, 1783–1799 (2021). https://doi.org/10.1007/s00170-021-07573-710.1007/s00170-021-07573-7 ↗
21. A. Mondal, P. Roy, S. Mitra, Experimental investigation on electro discharge machining of Ti-6Al-4V alloy. Adv. Mater. Process. Technol. 7(2), 262–272 (2021). https://doi.org/10.1080/2374068X.2020.175991310.1080/2374068X.2020.1759913 ↗
22. N. Ahmed, S. Ahmad, S. Anwar et al., Machinability of titanium alloy through laser machining: material removal and surface roughness analysis. Int. J. Adv. Manuf. Technol. 105, 3303–3323 (2019). https://doi.org/10.1007/s00170-019-04564-710.1007/s00170-019-04564-7 ↗
23. R. Farasati, P. Ebrahimzadeh, J. Fathi, R. Teimouri, Optimization of laser micromachining of Ti–6Al–4V. Int. J. Lightweight Mater. Manuf. 2, 305–317 (2019)
24. D. Sharma, S. Mohanty, A.K. Das, Surface modification of titanium alloy using hBN powder mixed dielectric through micro-electric discharge machining. Surf. Coat. Technol. 381, 125157 (2020)10.1016/j.surfcoat.2019.125157 ↗
25. M.M. Goud, A.K. Sharma, C.S. Jawalkar, A review on material removal mechanism in electrochemical discharge machining ECDM and possibilities to enhance the material removal rate. Precis. Eng. 45, 1–17 (2016). https://doi.org/10.1016/j.precisioneng.2016.01.00710.1016/j.precisioneng.2016.01.007 ↗
26. B. Bhattacharyya, B.N. Doloi, S.L. Sorkhel, Experimental investigations into electrochemical discharge machining (ECDM) of non-conductive ceramic materials. J. Mater. Process. Technol. 95, 145 (1999)10.1016/S0924-0136(99)00318-0 ↗
27. R. Wüthrich, U. Spaelter, Y. Wu, H. Bleuler, A systematic characterization method for gravity-feed micro-hole drilling in glass with spark assisted chemical engraving SACE. J. Micromech. Microeng. 16, 1891 (2006). https://doi.org/10.1088/0960-1317/16/9/01910.1088/0960-1317/16/9/019 ↗
28. R. Wuthrich, L.A. Hof, A. Lal, Physical principles and miniaturization of spark assisted chemical engraving (SACE). J. Micromech. Microeng. 15, 102005 (2005). https://doi.org/10.1088/0960-1317/15/10/S0310.1088/0960-1317/15/10/S03 ↗
29. V. Rajput, S.S. Pundir, M.M. Goud, N.M. Suri, Performance analysis of closed-loop electrochemical discharge machining (CLECDM) during micro-drilling and response surface methodology based multi-response parametric optimisation. Adv. Mater. Process. Technol. Silicon 13(5), 1619–1640 (2020). https://doi.org/10.1007/s12633-020-00538-710.1007/s12633-020-00538-7 ↗
30. S. Dong, Z. Wang, Y. Wang, High-speed electrochemical discharge drilling (HSECDD) for micro-holes on C17200 beryllium copper alloy in deionized water. Int. J. Adv. Manuf. Technol. 88, 827–835 (2017). https://doi.org/10.1007/s00170-016-8645-x10.1007/s00170-016-8645-x ↗
31. B.C. Xie, Y.K. Wang, Z. Wang, W. Zhao, Numerical simulation of titanium alloy machining in electric discharge machining process. Trans. Nonferrous Metals Soc. China 21(2), 434–439 (2011). https://doi.org/10.1016/S1003-6326(11)61620-810.1016/S1003-6326(11)61620-8 ↗
32. M. Calamaz, D. Coupard, F. Girot, A new material model for 2D numerical simulation of serrated chip formation when machining titanium alloy Ti–6Al–4V. Int. J. Mach. Tool Manuf. 48(3), 275–288 (2008). https://doi.org/10.1016/j.ijmachtools.2007.10.01410.1016/j.ijmachtools.2007.10.014 ↗
33. M.M. Goud, A.K. Sharma, A three-dimensional finite element simulation approach to analyze material removal in electrochemical discharge machining. Proc. IMechE Part C 231, 2417 (2016)10.1177/0954406216636167 ↗
34. V.S. Rajput, M.M. Goud, N.M. Suri, Finite element modelling for analyzing material removal rate in ECDM. J. Adv. Manuf. Syst. 19(4), 815–835 (2020). https://doi.org/10.1142/S021968672050036510.1142/S0219686720500365 ↗
35. K.L. Bhondwe, V. Yadava, G. Kathiresan, Finite element prediction of material removal rate due to electrochemical spark machining. Int. J. Mach. Tools Manuf. 46, 1699–1706 (2006). https://doi.org/10.1016/j.ijmachtools.2005.12.00510.1016/j.ijmachtools.2005.12.005 ↗
36. G. Singh, S.S. Sidhu, P.S. Bains et al., On surface modification of Ti alloy by electro discharge coating using hydroxyapatite powder mixed dielectric with graphite tool. J. Bio. Tribo. Corros. 6, 91 (2020). https://doi.org/10.1007/s40735-020-00389-010.1007/s40735-020-00389-0 ↗
37. V.S. Rajput, M.M. Goud, N.M. Suri, Numerical and experimental investigations to analyze the micro-hole drilling process in spark-assisted chemical engraving (SACE). SN Appl Sci 2, 1525 (2020)10.1007/s42452-020-03311-y ↗
38. R. Kumar, S. Roy, P. Gunjan, A. Sahoo, D.D. Sarkar, R.K. Das, Analysis of MRR and surface roughness in machining Ti–6Al–4V ELI titanium alloy using EDM process. Procedia Manuf. (2018). https://doi.org/10.1016/j.promfg.2018.02.05210.1016/j.promfg.2018.02.052 ↗
39. K. Sharma, A. Goyal, A.K. Sharma, Investigation of Material removal rate on Ti–6Al–4V super alloy. IOP Conf. Ser. (2020). https://doi.org/10.1088/1757-899X/810/1/01204510.1088/1757-899X/810/1/012045 ↗
40. L. Praveen, P.G. Krishna, L. Venugopal, N.E.C. Prasad, Effects of pulse ON and OFF time and electrode types on the material removal rate and tool wear rate of the Ti–6Al–4V alloy using EDM machining with reverse polarity. IOP Conf. Ser. (2018). https://doi.org/10.1088/1757-899X/330/1/01208310.1088/1757-899X/330/1/012083 ↗
41. I. Basak, A. Ghosh, Mechanism of material removal in electrochemical discharge machining a theoretical model and experimental verification. J. Mater. Process Tech. 71, 350–359 (1997). https://doi.org/10.1016/S0924-0136(97)00097-610.1016/S0924-0136(97)00097-6 ↗
42. A. Kulkarni, R. Sharan, G.K. Lal, An experimental study of discharge mechanism in electrochemical discharge machining. Int. J. Mach. Tool Manuf. 42, 1121–1127 (2002). https://doi.org/10.1016/S0890-6955(02)00058-510.1016/S0890-6955(02)00058-5 ↗
43. ASM Material Data sheet. http://asm.matweb.com/search/SpecificMaterial.asp?bassnum=MTP641, Retrieved 28 Jan 2022.
44. X. Yang, C. Richard Liu, Machining titanium and its alloys. Mach. Sci. Technol. 3(1), 107–139 (1999). https://doi.org/10.1080/1094034990894568610.1080/10940349908945686 ↗