Study of segmented chip formation in cutting of high-strength lightweight alloys

2021 ◽  
Author(s):  
Chao Zhang ◽  
Hongseok Choi
Keyword(s):  
Chip Formation ◽  
High Strength ◽  
Segmented Chip ◽  
Lightweight Alloys

scholarly journals Cutting force sensor based on digital image correlation for segmented chip formation analysis

2016 ◽  
Vol 238 ◽  
pp. 466-473 ◽  
Author(s):  
Thomas Baizeau ◽  
Sébastien Campocasso ◽  
Frédéric Rossi ◽  
Gérard Poulachon ◽  
François Hild
Keyword(s):  
Digital Image Correlation ◽  
Cutting Force ◽  
Digital Image ◽  
Chip Formation ◽  
Force Sensor ◽  
Image Correlation ◽  
Segmented Chip

A Finite Element Study of Chip Formation Process in Orthogonal Machining

2011 ◽  
Vol 1 (4) ◽  
pp. 19-45 ◽  
Author(s):  
Amrita Priyadarshini ◽  
Surjya K. Pal ◽  
Arun K. Samantaray
Keyword(s):  
Finite Element ◽  
Chip Formation ◽  
Critical Role ◽  
Fe Model ◽  
Orthogonal Machining ◽  
Adiabatic Shearing ◽  
Segmented Chip ◽  
The Right ◽  
Distribution Of Stress ◽  
Continuous Chip

This paper examines the plane strain 2D Finite Element (FE) modeling of segmented, as well as continuous chip formation while machining AISI 4340 with a negative rake carbide tool. The main objective is to simulate both the continuous and segmented chips from the same FE model based on FE code ABAQUS/Explicit. Both the adiabatic and coupled temperature displacement analysis has been performed to simulate the right kind of chip formation. It is observed that adiabatic hypothesis plays a critical role in the simulation of segmented chip formation based on adiabatic shearing. The numerical results dealing with distribution of stress, strain and temperature for segmented and continuous chip formations were compared and found to vary considerably from each other. The simulation results were also compared with other published results; thus validating the developed model.

The Microstructural Effects on Magnesium Alloy AZ31B-O While Undergoing an Electrically-Assisted Manufacturing Process

2009 ◽  
Author(s):  
Timothy A. McNeal ◽  
Jeffrey A. Beers ◽  
John T. Roth
Keyword(s):  
Deformation Process ◽  
Microstructural Analysis ◽  
High Strength ◽  
Strength Properties ◽  
High Demand ◽  
Electrically Assisted ◽  
Magnesium Alloy Az31b ◽  
Microstructural Effects ◽  
Lightweight Alloys ◽  
Electrically Assisted Manufacturing

In today’s industry, the need for lightweight alloys with high strength properties is growing. More specifically, magnesium alloys are in high demand. Unfortunately, magnesium’s limited formability hinders its broad range applicability. Previous research has discovered that the tensile formability of this alloy can be increased using electrical pulsing during the deformation process, referred to as Electrically-Assisted Manufacturing (EAM). Although this method increases a material’s formability (i.e. lowers flow stress, increases elongation, and reduces springback), a detailed analysis is required to further evaluate the effects of electricity on the material’s microstructure. The research herein will examine the microstructure of Magnesium AZ31B-O specimens that were deformed under uniaxial tension while electrically pulsed with various pulsing parameters (i.e. different current density/pulse duration combinations). This microstructural analysis will focus on how EAM affected grain size, grain orientation, and twinning. The microstructure of the following different specimen types will be compared: deformed EAM specimens, deformed non-pulsed baseline specimens, and undeformed non-pulsed “as received” specimens.

Effect of tool wear on chip formation during dry machining of Ti-6Al-4V alloy, part 1: Effect of gradual tool wear evolution

2015 ◽  
Vol 231 (9) ◽  
pp. 1559-1574 ◽  
Author(s):  
Shoujin Sun ◽  
Milan Brandt ◽  
Matthew S Dargusch
Keyword(s):  
Plastic Deformation ◽  
Tool Wear ◽  
Chip Formation ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Machined Surface ◽  
Segmented Chip ◽  
Gradual Development ◽  
Geometric Variables ◽  
On Chip

Geometric features of the segmented chip have been investigated along with the volume of material removed at a cutting speed at which tool wear is characterized by the gradual development of flank wear when cutting Ti-6Al-4V alloy. The chip geometric variables varied with an increase in the volume of material removed as the combined effect of change in tool’s geometry and increase in cutting temperature. Plastic deformation dimples were observed as periodical regions on the machined surface, a row on each undeformed surface and region on the top of the slipping surface of the segmented chip when cutting with new tool; these dimples on the undeformed surface and machined surface are elongated in the direction of chip flow. All these dimples became less with an increase in the volume of material removed and almost disappeared when the chip was removed with the worn tool at the end of its life. A model of segmented chip formation process has been proposed to satisfactorily explain the formation of the plastic deformation dimples on the undeformed surface and machined surface of the segmented chip produced with a new cutting tool and the transition of chip geometry with the evolution of tool wear.

Investigation on Chip Formation during Machining Using Finite Element Modeling

2012 ◽  
Vol 505 ◽  
pp. 31-36 ◽  
Author(s):  
Moaz H. Ali ◽  
Basim A. Khidhir ◽  
Bashir Mohamed ◽  
A.A. Oshkour
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Finite Element Modeling ◽  
Chip Formation ◽  
Cutting Tool ◽  
Chip Morphology ◽  
Machining Process ◽  
Element Modeling ◽  
Segmented Chip ◽  
Cutting Speeds

Titanium alloys are desirable materials for aerospace industry because of their excellent combination of high specific strength, lightweight, fracture resistant characteristics, and general corrosion resistance. Therefore, the chip morphology is very important in the study of machinability of metals as well as the study of cutting tool wear. The chips are generally classified into four groups: continuous chips, chips with built-up-edges (BUE), discontinuous chips and serrated chips. . The chip morphology and segmentation play a predominant role in determining machinability and tool wear during the machining process. The mechanics of segmented chip formation during orthogonal cutting of titanium alloy Ti–6Al–4V are studied in detail with the aid of high-speed imaging of the chip formation zone. The finite element model of chip formation of Ti–6Al–4V is suggested as a discontinuous type chip at lower cutting speeds developing into a continuous, but segmented, chip at higher cutting speeds. The prediction by using finite-element modeling method and simulation process in machining while create chips formation can contribute in reducing the cost of manufacturing in terms of prolongs the cutting tool life and machining time saving.

Gezielte Begrenzung der Spandickenschwankungen/Development of a counter element for influencing chip formation when machining titanium. Restriction of chip thickness deviations

2020 ◽  
Vol 110 (11-12) ◽  
pp. 806-810
Author(s):  
Sebastian Berger ◽  
Jannis Saelzer ◽  
Dirk Biermann
Keyword(s):  
Titanium Alloy ◽  
Surface Quality ◽  
Tool Life ◽  
Chip Formation ◽  
Chip Thickness ◽  
Vibration Damping ◽  
Suitable Choice ◽  
Periodic Excitation ◽  
Segmented Chip ◽  
Titanium Alloy Ti6al4v

Dieser Beitrag stellt die simulative Analyse zum Einfluss eines begrenzenden Elements zur Unterdrückung der Segmentspanbildung bei der Zerspanung der Titanlegierung Ti6Al4V vor. Dabei lässt sich aufzeigen, dass eine spanbildungsinduzierte periodische Anregung des Systems durch die geeignete Wahl von Geometrie und Positionierung des Elementes verhindert werden kann, wodurch sich die Werkzeugstandzeit und die Oberflächenqualität verbessern und schwingungsdämpfende Maßnahmen obsolet werden. This paper presents the simulative analysis of the influence of a counter element for the suppression of segmented chip formation during the machining of titanium alloy Ti6Al4V. It is shown that a chip formation induced periodic excitation of the system can be prevented by a suitable choice of geometry and positioning of the element, leading to increased tool life and surface quality as well as making vibration damping methods obsolete.

The Effect of Ti-6Al-4V Microstructure, Cutting Speed, and Adiabatic Heating on Segmented Chip Formation and Tool Life

JOM ◽  
2022 ◽  
Author(s):  
Ryan M. Khawarizmi ◽  
Jiawei Lu ◽  
Dinh S. Nguyen ◽  
Thomas R. Bieler ◽  
Patrick Kwon
Keyword(s):  
Tool Life ◽  
Chip Formation ◽  
Cutting Speed ◽  
Adiabatic Heating ◽  
Segmented Chip

Evidence of thermoplastic instability about segmented chip formation process for Ti–6Al–4V alloy based on the finite-element method

2011 ◽  
Vol 225 (6) ◽  
pp. 1407-1417 ◽  
Author(s):  
G Chen ◽  
C Ren ◽  
X Yang ◽  
T Guo
Keyword(s):  
Finite Element ◽  
Formation Mechanism ◽  
Failure Criterion ◽  
Formation Process ◽  
Chip Formation ◽  
Deformation Zone ◽  
Chip Morphology ◽  
Fe Model ◽  
Friction Characteristic ◽  
Segmented Chip

A ductile failure law and an energy-based failure criterion have been implemented in a 2D finite-element (FE) model to simulate the segmented chip formation process in titanium alloy (Ti–6Al–4V) machining. The variations of stress and strain are taken into account in defining the material failure criterion. The cutting forces and chip morphology calculated by FE model are compared with experimental results in good agreement, validating the FE model. Stresses, strains, cutting temperatures, and stiffness degradation along adiabatic shear bands (ASBs) are analysed during the segment formation process to investigate the segment formation mechanism. It is found that the variation trend of strains is the same as that of temperatures, in addition, the variation of strains and their changing-rate lag slightly behind those of temperatures. These observations provide a new evidence of thermoplastic instability along ASB and increase the understanding of segmented chip formation mechanism. Furthermore, simulation results show that ASB morphology and its forming mechanism are mainly caused by thermoplastic instability in primary deformation zone and friction characteristic in the second deformation zone.

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