Study on the cutting characteristics of high-speed machining Zr-based bulk metallic glass

• Published in: International journal of advanced manufacturing technology 2022-03, Vol.119 (5-6), p.3533-3544
• Main Authors: Yang, Haidong, Wu, Yusong, Zhang, Junsheng, Tang, Huohong, Chang, Weijie, Zhang, Juchen, Chen, Shunhua
• Format: Article
• Language: English
• Subjects: Amorphous materials; CAE) and Design; Chip formation; Chips; Computer-Aided Engineering (CAD; Cutting force; Cutting parameters; Cutting speed; Cutting wear; Droplets; Edge dislocations; Engineering; Free surfaces; Grooves; High speed machining; Industrial and Production Engineering; Low speed; Machine shops; Machine tools; Mechanical Engineering; Media Management; Metallic glasses; Morphology; Original Article; Oxidation; Shear bands; Surface properties; Surface roughness; Tool wear; Workpieces
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-021-08630-x

The cutting characteristics of high-speed machining (100–350 m/min) Zr 57 Cu 20 Al 10 Ni 8 Ti 5 (at.%) bulk metallic glass (Zr57 BMG) were studied, as compared with industrial pure zirconium (Zr702). The effect of cutting speed on cutting force, surface roughness, surface morphology, chip morphology, and tool wear was analyzed. Although the strength of Zr57 BMG is much higher than that of Zr702, there is no significant difference between the main cutting forces of the two materials, which can be attributed to the thermal softening of Zr57 BMG material during machining. The machined surface characteristics and the formation of chips were investigated. Differing from low-speed machining, the groove marks and adhensions on machined surface evolve to wave patterns and molten droplets when the cutting speed increased from 100 to 350 m/min. The appearance of wave patterns tends to destroy the machined surfaces, and the worst quality was obtained at the speed of 250 m/min. The free surface morphology of the chips, with cutting speed smaller than 150 m/min, show obvious serration and molten droplets between the shear bands. With the increase of cutting speed, oxidation on the chip surfaces occurred, and the chip surface was gradually covered by powder particles due to the melting of Zr57 BMG workpiece materials. The wear behavior of the flank faces of cutting tools was also examined. After high-speed machining, the machined surfaces of the Zr57 BMG still maintain the amorphous atomic structures. The cutting parameters at relatively high cutting speed (from 250 to 350 m/min) were further optimized for improving the machined surface quality. The present findings are of significance for the processing of BMG and BMG components by use of high-speed machining.