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Stephen Jimenez MSc Thesis
35
Operated by Los Alamos National Security, LLC for NNSA P.O. Box 1663 This document deemed Unclassified by _______________________________ (DC) UNCLASSIFIED UNCLASSIFIED THE EFFECTS OF DRY MACHINING ON THE SURFACE PROPERTIES OF PURE COPPER Master Thesis Defense Presentation November 16, 2012 By Stephen Jimenez Committee: Dr. T.D. Burleigh Dr. D. Quintana Dr. J. McCoy Dr. N. Kalugin New Mexico Institute of Mining and Technology Department of Material and Metallurgical Engineering Ronnie Parker LA-UR-12-26076
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Transcript of Stephen Jimenez MSc Thesis
Operated by Los Alamos National Security, LLC for NNSA
P.O. Box 1663
LA-UR-xx-xxxx/W-x-xx-xxxx
This document deemed Unclassified by
_______________________________
(DC)
UNCLASSIFIED
UNCLASSIFIED
THE EFFECTS OF DRY MACHINING ON THE
SURFACE PROPERTIES OF PURE COPPER
Master Thesis Defense Presentation
November 16, 2012
By Stephen Jimenez
Committee:
Dr. T.D. Burleigh
Dr. D. Quintana
Dr. J. McCoy
Dr. N. Kalugin
New Mexico Institute of Mining and Technology
Department of Material and Metallurgical Engineering
Ronnie Parker
LA-UR-12-26076
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Machining Background
Machining
• Remove Material
Methods
• Milling
• Boring
• Drilling
• Turning
Cutting Fluid Added
• Heat Convection
• “Wet Machining”
• Very Efficient
Slide 2
ww.engineerlive.com/Process-Engineer/Process_Equipment/Coolants
LA-UR-12-26076
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Research Motivation
Why Dry Machining?
Worker Safety
• Chronic Respiratory Diseases
• Chronic Skin Disorders
• Increase Risk of Cancer
Environmental Impact
• 7% - 11% Manufacture Costs (Donohue, 2007)
Economic
• Recycling $$$$
Slide 3
LA-UR-12-26076
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Previous Work on Testing/Machining Copper
Ni & Alpas, 2003
• DRX
• Within Machined Chip (MC)
Elmadagli & Alpas, 2003
• Brinell Hardness (BHN)
Bissey-Breton et al., 2011
• Linear Relationship Surface
— Ra vs. DL
Slide 4
(Elmadagli & Alpas, 2003)
LA-UR-12-26076
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Problem Definition
Dry Machining Copper
• Machining Parameters Not Well Understood
Machining Parameters
• Depth of Cut (DOC)
• Feed
• Surface Speed
• Spindle Speed
Produce Good Surface Roughness
• How Will DOC Affect the Mechanical Properties?
Slide 5
LA-UR-12-26076
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Thesis Statement
Varying DOC
All Other Parameters Constant
Good Surface Finish Achievable
Mechanical Properties
• Can be Manipulated
Slide 6
http://www.jamesriser.com/SmSacCoins/Machining.html, 2012
LA-UR-12-26076
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Methods – Merchant’s Model (1945)
Shear Angle (φ)
Shear Strain (γ)
Slide 7
LA-UR-12-26076
φ
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Methods – Automated Ball Indentation (ABI)
Force vs. Indentation Depth
Estimates
• BHN
• Yield Stress (YS)
• Ultimate Tensile Stress (UTS)
Parabolic Hardening Function
• Strength Coefficient (K)
• Strain Hardening (n)
Slide 8
T1-Sample
LA-UR-12-26076
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Methods – Optical Microscopy
Slide 9
T3 -Sample T1-Sample
Etch Pits
DL
LA-UR-12-26076
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Background - Turning Process
Work Piece Rotated
Axial Direction
Helical Cutting Path
Slide 10
LA-UR-12-26076
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
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Background - Machined Chip/Work-Piece
Slide 11
• Rake Face (RF)
• Secondary Deformation Zone (SDZ)
• Machined Chip (MC)
• Point of Contact (POC)
• Machined Surface (MS)
• Primary Deformation Zone (PDZ)
• Deformation Free Zone (DFZ)
MC
SDZ
RF
POC
MS
PDZ DFZ
LA-UR-12-26076
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Background - PDZ
Slide 12
Heavy Deformation in MC
Highest Strains in PDZ
MC Thickness > DOC
LA-UR-12-26076
Elongated Lamellar Structure
PDZ T1 Chip Rake Face
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
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Background - Chip Morphology
Slide 13
Continuous Chip Dis-continuous Chip
Continuous Chip w/BUE Serrated Chip
LA-UR-12-26076
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Background - Surface Finish
Surface Roughness (Ra)
Surface Waviness (Wa)
Lay Pattern
Slide 14
Recreated (ASME B46.1-2009)
LA-UR-12-26076
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Background – Copper Properties
FCC Structure
• 12 Slip Systems
Modern Applications
• Wiring
• Commercial Piping
• Roofing Materials
C11000 ETP H80
• Wrought copper
• Low Impurities
Slide 15
T3 - Sample
LA-UR-12-26076
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Experimental Procedure - Machining
Kent (USA) ML-20 x 60 Manual Lathe
• L-Sample Set (6 Samples Total)
Leblond Regal Manual Lathe
• T-Sample Set (6 Samples Total)
Kennametal KD100 PCD Insert
• Non-ferrous Machining
Machining Parameters
• L-Sample Set Varied
• T-Sample Only DOC Varied
Slide 16
LA-UR-12-26076
Leblond Regal
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Experimental Procedures Ra Measurement
Mahr Perthometer PCV XCR20
• Los Alamos Laboratory
LANL Calibration Standards
B46.1 -2009 (ASME B46.1 – 2009)
Slide 17
http://www.join-star.com.tw/joinstar2_3.asp?num=680, 2012g
LA-UR-12-26076
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Experimental Procedure - Optical Microscopy
Hirox KH7700 (OL 35 lens) NMT
• L & T – Sample Set
— Analyzed
Olympus GX41 NMT
• T-Sample
— Analyzed
Zeiss AxioCam HRc LANL
• T-Sample
— Analyzed
Slide 18
LA-UR-12-26076
Olympus GX41
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Experimental Procedure - Sample Preparation
~25 mm Diameter X 25 mm Long
T-Sample Set Cold Mounted
Polished
• 0.3um Alpha Alumina
Etched
• 50/50 H2O2 – NaOH
Slide 19
LA-UR-12-26076
T-Sample Cold Mount
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
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Mathematical Treatments - Strain
Principal Strains
Volume Strain
Distortion Energy
Slide 20
LA-UR-12-26076
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Mathematical Treatments - Dislocation Density (Butler,
Etch Pits (ρi) Dislocation Density (ρl)
Assumptions
— Dislocation Angle = Constant
Slide 21
LA-UR-12-26076
φ
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Mathematical Treatments - Adiabatic Temperature Rise
Assumptions
• RT~ 25° C
• No Heat Loss
Work
• Parabolic Function
Integrate
Slide 22
LA-UR-12-26076
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Experimental Results
L-Sample Micrographs
• Machining Parameters
— Standard Practices
Tool Marks
Some Chatter
No Difference
Slide 23
L1 – Sample
Surface
LA-UR-12-26076
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
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Experimental Results
T-Sample Set
• Varied DOC Only!
Slide 24
0.06 0.13
0.25
0.51
1.02
2.03
0.00
0.50
1.00
1.50
2.00
2.50
0 1 2 3 4 5 6
DOC (mm)
T-Sample Identification Number
LA-UR-12-26076
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Experimental Results
Perthometer Results
• L-Sample
— Ra ~ Equal
• T-Sample
— Differences Noted
Slide 25
0
1
2
3
4
5
6
7
8
0 1 2 3 4 5 6
Ra
(u
m)
Sample Identification Number
L-samples
T-samples
LA-UR-12-26076
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UNCLASSIFIED
Experimental Results
T-Sample Micrographs
• Damaged Surface
• Etch Pits
• Twins
• DL
Zeiss
— Elongated Cell Structure
T6 -Sample
LA-UR-12-26076
T6-sample surface
T6-Sample
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Experimental Results - ABI
Work Hardening Increased
T3 & T4 Highest Stress
Slide 27
0
50
100
150
200
250
300
350
400
0 1 2 3 4 5 6
Wo
rk H
ard
enin
g -
FR
AC
(M
Pa
)
T-Sample Identification Number
LA-UR-12-26076
Trend Line Only
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Experimental Results - ABI
True Stress vs. True Strain
Slide 28
0
50
100
150
200
250
300
350
400
450
500
0 0.2 0.4 0.6 0.8 1 1.2
Tru
e S
tres
s (M
pa
)
True Strain
T1
T2
T3
T4
T5
T6
LA-UR-12-26076
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UNCLASSIFIED
Theoretical Results – Shear Strain
Increase w/DOC
T4 Lowest Shear
Slide 29
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
0 1 2 3 4 5 6
Ra
dia
ns
T-Sample Identification Number
Shear Angle
Shear
LA-UR-12-26076
Trend Line Only
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Theoretical Results – Dislocation Density
Slight Increase
T4 Highest Value
Slide 30
0.0E+00
2.0E+09
4.0E+09
6.0E+09
8.0E+09
1.0E+10
1.2E+10
1.4E+10
1.6E+10
0 1 2 3 4 5 6
Dis
loca
tio
n D
ensi
ty (
m^
-2)
T-Sample Identification Number
Trend Line Only
LA-UR-12-26076
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Theoretical Results – Max Adiabatic Temperature
T6 Highest Temperature
Slide 31
0
50
100
150
200
250
300
350
400
450
0 1 2 3 4 5 6
Sh
ear
Pla
ne
Tem
per
atu
re (°C
)
T-Sample Identification Number
Recrystallization Temperature Zone
LA-UR-12-26076
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UNCLASSIFIED
Final Results
Ra vs. DOC
Slide 32
0
1
2
3
4
5
6
7
8
0 1 2 3 4 5 6
Ra
(u
m)
T-Sample Identification Number
LA-UR-12-26076
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Conclusions
DOC Increased
• Shear Angle/Shear Strain
• Increase Dislocation Density
Parabolic Hardening Function
• T1 & T2 Lowest Stress
• T3 & T4 Highest Stress
Average temperature:
• Mean Range (T1 – T4) 145°C
Optimal DOC Range (T1 to T4)
• Lowest DOC’s (T1 & T2) Good Ra Low BHN
• Deeper DOC’s (T3 & T4) ~ Same Ra Higher BHN
Slide 33
LA-UR-12-26076
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Future Work
DOC Range (T1-T4)
• Vary Remaining Machining Parameters
— Feed, Speed, Spindle Speed
Measure Ra
• Perthometer
Estimate Mechanical Properties
• ABI
Temperature Determination
• Thermal Camera
• Record Residual Temperature & Rate of Cooling
TEM
• Determine Microstructure in DL
• Correlate with Residual Temperature, Mechanical Properties & Ra
Slide 34
LA-UR-12-26076
Operated by Los Alamos National Security, LLC for NNSA LA-UR-xx-xxxx/W-x-xx-xxxx UNCLASSIFIED
UNCLASSIFIED
Thank You! Los Alamos National Laboratory
• Thesis Subject
• Lab Use
• Machine Shop SM 39
Institute of Mining and Technology
• Lab Use
• Metallography Lab
• R & D Machine Shop
Magdalena Ridge Observatory
• Academic Support
My Wife Michelle
• Everything!
Slide 35
LA-UR-12-26076
