scholarly journals Improved analytical prediction of chip formation in orthogonal cutting of titanium alloy Ti6Al4V

2017 ◽  
Vol 133 ◽  
pp. 357-367 ◽  
Author(s):  
Wei Bai ◽  
Ronglei Sun ◽  
Anish Roy ◽  
Vadim V. Silberschmidt
Keyword(s):  
Titanium Alloy ◽  
Chip Formation ◽  
Orthogonal Cutting ◽  
Analytical Prediction ◽  
Titanium Alloy Ti6al4v

scholarly journals Analytical modelling of cutting forces in near-orthogonal cutting of titanium alloy Ti6Al4V

2014 ◽  
Vol 229 (6) ◽  
pp. 1122-1133 ◽  
Author(s):  
Yun Chen ◽  
Huaizhong Li ◽  
Jun Wang
Keyword(s):  
Titanium Alloy ◽  
Cutting Forces ◽  
Chemical Reactivity ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Analytical Modelling ◽  
Shear Instability ◽  
Published Data ◽  
Machining Processes ◽  
Titanium Alloy Ti6al4v

Titanium and its alloys are difficult to machine due to their high chemical reactivity with tool materials and low thermal conductivity. Chip segmentation caused by the thermoplastic instability is always observed in titanium machining processes, which leads to varied cutting forces and chip thickness, etc. This paper presents an analytical modelling approach for cutting forces in near-orthogonal cutting of titanium alloy Ti6Al4V. The catastrophic shear instability in the primary shear plane is assumed as a semi-static process. An analytical approach is used to evaluate chip thicknesses and forces in the near-orthogonal cutting process. The shear flow stress of the material is modelled by using the Johnson–Cook constitutive material law where the strain hardening, strain rate sensitivity and thermal softening behaviours are coupled. The thermal equations with non-uniform heat partitions along the tool–chip interface are solved by a finite difference method. The model prediction is verified with experimental data, where a good agreement in terms of the average cutting forces and chip thickness is shown. A comparison of the predicted temperatures with published data obtained by using the finite element method is also presented.

scholarly journals Constitutive Model and Cutting Simulation of Titanium Alloy Ti6Al4V after Heat Treatment

Materials ◽  
2019 ◽  
Vol 12 (24) ◽  
pp. 4145
Author(s):  
Xiaohua Qian ◽  
Xiongying Duan
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Titanium Alloy ◽  
Orthogonal Cutting ◽  
Treatment Method ◽  
Dynamic Mechanical Properties ◽  
Ti6al4v Alloy ◽  
Stress Strain ◽  
Cutting Simulation ◽  
Titanium Alloy Ti6al4v

As a typical high specific strength and corrosion-resistant alloy, titanium alloy Ti6Al4V is widely used in the aviation, ocean, biomedical, sport, and other fields. The heat treatment method is often used to improve the material mechanical properties. To investigate the dynamic mechanical properties of titanium alloy Ti6Al4V after heat treatment, dynamic compressive experiments under high temperature and high strain rate were carried out using split Hopkinson press bar (SHPB) equipment. The stress–strain curves of Ti6Al4V alloy under different temperatures and strain rates were obtained through SHPB compressive tests. The Johnson–Cook (J–C) constitutive equation was used for expressing the stress–strain relationship of titanium alloy under large deformation. In addition, the material constants of the J–C model were fitted based on the experimental data. An orthogonal cutting simulation was performed to investigate the cutting of Ti6Al4V alloy under two different numerical calculation methods based on the established J–C model using the finite element method (FEM). The simulation results confirm that the adiabatic mode is more suitable to analyze the cutting of Ti6Al4V alloy.

Study on Determination of Friction Model at the Tool-Chip Interface of Titanium Alloy Ti6Al4V Based on Orthogonal Cutting

2011 ◽  
Vol 117-119 ◽  
pp. 1788-1791
Author(s):  
Yue Feng Yuan ◽  
Wu Yi Chen
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Friction Model ◽  
Carbide Tool ◽  
Orthogonal Turning ◽  
Titanium Alloy Ti6al4v

It is necessary for cutting simulation to determine the friction model at the tool-chip interface suitable for metal cutting process. Cutting force experiments in orthogonal turning titanium alloy TI6AL4V are carried out with cement carbide tool KW10. The Coulomb frictions at the tool-chip interface are calculated based on measured cutting force, and the friction model is regressed, where cutting speed and feed rate are presented.

FEA Simulation of the Influence of Cutting Parameters on Serrated Chip Formation in Machining Titanium Alloy Ti-6Al-4V

2012 ◽  
Vol 500 ◽  
pp. 152-156
Author(s):  
Zeng Hui Jiang ◽  
Ji Lu Feng ◽  
Xiao Ye Deng
Keyword(s):  
Titanium Alloy ◽  
Chip Formation ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Element Model ◽  
Serrated Chip ◽  
Wide Range ◽  
Serrated Chip Formation ◽  
Fea Simulation

A finite element model of a two dimensional orthogonal cutting process is developed. The simulation uses standard finite software is able to solve complex thermo-mechanical problems. A thermo-visco-plastic model for the machined material and a rigid cutting tool were assumed. One of the main characteristic of titanium alloy is serrated shape for a wide range of cutting conditions. In order to understand the influence of cutting parameters on the chip formation when machining titanium alloy Ti-6Al-4V. The influence of the cutting speed,the cutting depth and the feed on the chip shape giving rise to segmented chips by strain localisation is respectively discussed.

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.

scholarly journals Predictive modelling of cutting forces in end milling of titanium alloy Ti6Al4V

2016 ◽  
Vol 232 (9) ◽  
pp. 1523-1534 ◽  
Author(s):  
Yun Chen ◽  
Huaizhong Li ◽  
Jun Wang
Keyword(s):  
Titanium Alloy ◽  
Predictive Model ◽  
End Milling ◽  
Mechanistic Model ◽  
Orthogonal Cutting ◽  
Cutting Edge ◽  
Material Strength ◽  
Force Model ◽  
Serrated Chip ◽  
Titanium Alloy Ti6al4v

A cutting force model, based on a predictive model for orthogonal cutting, is developed for force predictions in end milling of titanium alloy Ti6Al4V. The model assumes a semi-stationary process for the serrated chip formation. The Johnson–Cook material model that couples strain hardening, strain rate sensitivity and thermal softening effects is applied to represent the material strength. A thermal model considering the tool thermal properties is integrated to account for the high temperature rise due to the low thermal conductivity of Ti6Al4V. To extend the predictive model to milling, the end mill is discretised into several axial slices, and an equivalent cutting edge is used to include the end cutting edge effect caused by the first axial slice. The model is assessed by comparing its prediction with the experimental results and a mechanistic model for verification. The results show that the proposed model outperforms the mechanistic model with higher accuracy in force prediction.

Analytical Prediction of Three Dimensional Cutting Process—Part 1: Basic Cutting Model and Energy Approach

1978 ◽  
Vol 100 (2) ◽  
pp. 222-228 ◽  
Author(s):  
E. Usui ◽  
A. Hirota ◽  
M. Masuko
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Single Point ◽  
Orthogonal Cutting ◽  
Three Dimensional ◽  
Analytical Prediction ◽  
Forming Process ◽  
Proposed Model ◽  
Edge Based ◽  
Cutting Model

The paper proposes a new model of chip forming process in three dimensional cutting with single point tool, in which the process is interpreted as a piling up of orthogonal cuttings along the cutting edge. Based upon the proposed model, an energy method similar to the upper bound approach, which enables to predict the chip formation and the three components of cutting force by using only the orthogonal cutting data, is developed. The method is also applied to predict chip formation and cutting force in oblique cutting, plain milling, and groove cutting operations.

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