Numerical study of chip formation and cutting force in high-speed machining of Ti-6Al-4V bases on finite element modeling with ductile fracture criterion

2021 ◽  
Author(s):  
Mehmet Aydın
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Ductile Fracture ◽  
Cutting Force ◽  
Chip Formation ◽  
High Speed ◽  
Fracture Criterion ◽  
Numerical Study ◽  
High Speed Machining ◽  
Ductile Fracture Criterion

Numerical Simulation of Cutting Force and Temperature Field in High Speed Machining of Titanium Alloys

2010 ◽  
Vol 37-38 ◽  
pp. 731-734 ◽  
Author(s):  
Cong Ming Yan ◽  
You Xi Lin
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Chip Formation ◽  
High Speed ◽  
Metal Cutting ◽  
Rake Angle ◽  
Maximum Temperature ◽  
High Speed Machining ◽  
Force Fluctuation ◽  
Cutting Force Fluctuation

Improvements in manufacturing technologies require better modeling and simulation of metal cutting processes. A fully thermal-mechanical coupled finite element analysis (FEA) was applied to model and simulate the high speed machining of TiAl6V4. The development of serrated chip formation during high speed machining was simulated. The effects of rake angle on chip morphology, cutting force and the evolution of the maximum temperature at the tool rake were analyzed with the finite element model. The simulation results show that the segmented chip formation results in cutting force fluctuation. Although the segmentation frequency of the chip increases with the increase of the rake angle, the degree of segmentation becomes weaker and the cutting force fluctuation amplitude decreases. The predicted temperature distribution during the cutting process is consistent with the experimental results given in a literature.

scholarly journals Finite Element Analysis of Bore-expanding Processes with Ductile Fracture Criterion

1998 ◽  
Vol 84 (3) ◽  
pp. 182-187 ◽  
Author(s):  
Hirohiko TAKUDA ◽  
Ken-ichiro MORI ◽  
Masashi KANESHIRO ◽  
Natsuo HATTA
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Ductile Fracture ◽  
Fracture Criterion ◽  
Ductile Fracture Criterion ◽  
Element Analysis

Comparative Study on Cutting Force Simulation Using DEFORM 3D Software during High Speed Machining of Ti-6Al-4V

2020 ◽  
Vol 856 ◽  
pp. 50-56
Author(s):  
Kundan Kumar Prasad ◽  
Santosh Kumar Tamang ◽  
M. Chandrasekaran
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Temperature ◽  
Experimental Result ◽  
Depth Of Cut ◽  
Work Piece ◽  
High Speed Machining ◽  
3D Software ◽  
Deform 3D

The finite element-based machining simulations for evaluation/computation of different machining responses (i.e., cutting temperature, tool wear, cutting force, and power/energy consumption) are investigated by number of researchers. In this work, finite element machining simulation was performed to obtain knowledge about cutting forces during machining of hard materials. Titanium alloy (Ti-6Al-4V) has been increasingly used in aerospace and biomedical applications due to high toughness and good corrosion resistance. The high speed machining (HSM) simulation of Ti-6Al-4V work-piece using carbide tool coated with TiCN has been conducted with different combination of cutting conditions for prediction of main cutting force (Fz). The simulated result obtained from Deform 3D software is validated with experimental result and it was found that the result found in good agreement. The parametric variation shows that depth of cut and feed are influencing parameters on cutting force.

Prediction and analysis of ductile fracture in sheet metal forming—Part I: A modified Ayada criterion

2014 ◽  
Vol 23 (8) ◽  
pp. 1189-1210 ◽  
Author(s):  
HS Liu ◽  
MW Fu
Keyword(s):  
Finite Element ◽  
Plastic Strain ◽  
Ductile Fracture ◽  
Sheet Metal ◽  
Sheet Metal Forming ◽  
Metal Forming ◽  
Fracture Criterion ◽  
Ductile Fracture Criterion ◽  
Wide Range ◽  
Stress States

A modified ductile fracture criterion is proposed based on the traditional Ayada criterion and coded into the finite element simulation platform of VUMAT/ABAQUS for prediction and analysis of ductile fracture in metal plastic strain processes. In this modified ductile fracture criterion, stress triaxiality is taken into account, and more importantly, the exponential effect of the equivalent plastic strain on the damage behavior, which is generally ignored in other ductile fracture criteria, is also considered. The material related constants in the modified ductile fracture criterion are determined by tensile tests together with finite element simulations. The applicability and reliability of the ductile fracture criterion in ductile fracture prediction in two types of classic stress states, viz. shear stress, tensile stress in sheet metal forming, are investigated based on the deformation behavior and fracture occurrence in two case studies with two typical types of materials, i.e. Al 6061 and T10A. The materials have a wide range of plasticity. The simulation and experimental results verify the applicability and reliability of the developed ductile fracture criterion in prediction of the ductile fracture with and without necking in different stress states of plastic strain.

L16 Orthogonal Array-Based Three-Dimensional Finite Element Modeling for Cutting Force and Chip Formation Analysis During Dry Machining of Ti–6Al–4V

2020 ◽  
pp. 1-12
Author(s):  
Raviraj Shetty ◽  
Sanjeev Kumar ◽  
Ravindra Mallagi ◽  
Laxmikanth Keni
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Cutting Force ◽  
Chip Formation ◽  
Orthogonal Array ◽  
Three Dimensional ◽  
Cutting Conditions ◽  
Element Modeling ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element

The outstanding characteristics of titanium alloy (Ti–6Al–4V) have made this material applicable in aerospace and medical components. However, due to its poor machinability characteristics, researchers are forced to understand the machinability behavior of Ti–6Al–4V. In this paper, [Formula: see text] orthogonal array-based three-dimensional finite element modeling for the cutting force and chip formation analysis during the machining of Ti–6Al–4V using cubic boron nitride tool in dry turning environment has been investigated. The finite element simulation was performed using ANSYS Workbench, version 19.0. Cutting force and chip formation were investigated using the results obtained from [Formula: see text] orthogonal array-based three-dimensional finite element modeling. This research would help to identify the optimum cutting conditions and minimize the cutting force followed by analyzing the types of chips formed during machining under the selected set of cutting conditions.

Investigation of the Impact Analysis of Microscale Thin-Walled Structures Manufactured by High-Speed Machining

2006 ◽  
Vol 326-328 ◽  
pp. 1599-1602
Author(s):  
Bo Sung Shin
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
High Speed ◽  
Impact Analysis ◽  
Thin Wall ◽  
High Speed Machining ◽  
High Speed Cutting ◽  
Thin Walled Structures ◽  
Thin Walled ◽  
The Impact

High-speed machining (HSM) is very useful method as one of the most effective manufacturing processes because it has excellent quality and dimensional accuracy for precision machining. Recently micromachining technologies of various functional materials with very thin walls are needed in the field of electronics, mobile telecommunication and semiconductors. However, HSM is not suitable for microscale thin-walled structures because of the lack of their structure stiffness to resist high-speed cutting force. A microscale thin wall machined by HSM shows the characteristics of the impact behavior because the high-speed cutting force works very shortly on the machined surface. We propose impact analysis model in order to predict the limit thickness of a very thin-wall and investigate its limit thickness of thin-wall manufactured by HSM using finite element method. Also, in order to verify the usefulness of this method, we will compare finite element analyses with experimental results and demonstrate some applications.

Finite Element Simulation and Experiment of Chip Formation during High Speed Cutting of Hardened Steel

2010 ◽  
Vol 29-32 ◽  
pp. 1838-1843 ◽  
Author(s):  
Chun Zheng Duan ◽  
Hai Yang Yu ◽  
Yu Jun Cai ◽  
Yuan Yuan Li
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
High Speed ◽  
Chip Morphology ◽  
Hardened Steel ◽  
High Speed Machining ◽  
Serrated Chip ◽  
High Speed Cutting ◽  
Element Simulation ◽  
Aisi 1045

As an advanced manufacturing technology which has been developed rapidly in recent years, high speed machining is widely applied in many industries. The chip formation during high speed machining is a complicated material deformation and removing process. In research area of high speed machining, the prediction of chip morphology is a hot and difficult topic. A finite element method based on the software ABAOUS which involves Johnson-Cook material model and fracture criterion was used to simulate the serrated chip morphology and cutting force during high speed cutting of AISI 1045 hardened steel. The serrated chip morphology and cutting force were observed and measured by high speed cutting experiment of AISI 1045 hardened steel. The effects of rake angle on cutting force, sawtooth degree and space between sawteeth were discussed. The investigation indicates that the simulation results are consistent with the experiments and this finite element simulation method presented can be used to predict the chip morphology and cutting force accurately during high speed cutting of hardened steel.

Finite Element Modeling of Cutting Force and Chip Formation During Thermally Assisted Machining of Ti6Al4V Alloy

2013 ◽  
Vol 135 (6) ◽  
Author(s):  
Yao Xi ◽  
Michael Bermingham ◽  
Gui Wang ◽  
Matthew Dargusch
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Cutting Force ◽  
Formation Process ◽  
Chip Formation ◽  
Cutting Forces ◽  
Experimental Results ◽  
Strongly Correlated ◽  
Element Modeling ◽  
Simulation Results

The improvement in machinability during thermally assisted turning of the Ti-6Al-4V alloy has been investigated using finite element modeling. A 2D thermally assisted turning model was developed and validated by comparing the simulation results with experimental results. The effect of workpiece temperature on the cutting force and chip formation process was examined. The predicted cutting forces and chip morphologies from the simulation strongly correlated with the experimental results. It was observed from the simulation that the chip forms after the coalescence of two deformed regions in the shear band and that the cyclic cutting forces are strongly related to this chip formation process.

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