Influence of the Choice of the Parameters on Constitutive Models and their Effects on the Results of Ti6Al4V Orthogonal Cutting Simulation

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.

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Influence of constitutive models on finite element simulation of chip formation in orthogonal cutting of Ti-6Al-4V alloy

Procedia Manufacturing ◽

10.1016/j.promfg.2019.04.066 ◽

2019 ◽

Vol 33 ◽

pp. 530-537 ◽

Cited By ~ 2

Author(s):

Guang Chen ◽

Lianpeng Lu ◽

Zhihong Ke ◽

Xuda Qin ◽

Chengzu Ren

Keyword(s):

Finite Element ◽

Finite Element Simulation ◽

Chip Formation ◽

Orthogonal Cutting ◽

Constitutive Models ◽

Element Simulation

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The Effect of Material Parameters on Chip Formation in Orthogonal Cutting Simulation of Ti-5553 Alloy

Procedia CIRP ◽

10.1016/j.procir.2017.03.324 ◽

2017 ◽

Vol 58 ◽

pp. 305-310 ◽

Cited By ~ 6

Author(s):

Melih Ozkutuk ◽

Yusuf Kaynak

Keyword(s):

Chip Formation ◽

Orthogonal Cutting ◽

Cutting Simulation ◽

Material Parameters ◽

On Chip

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Dislocation Density Based Flow Stress Model Applied to the PFEM Simulation of Orthogonal Cutting Processes of Ti-6Al-4V

Materials ◽

10.3390/ma13081979 ◽

2020 ◽

Vol 13 (8) ◽

pp. 1979 ◽

Cited By ~ 1

Author(s):

Juan Manuel Rodríguez ◽

Simon Larsson ◽

Josep Maria Carbonell ◽

Pär Jonsén

Keyword(s):

Dislocation Density ◽

Constitutive Model ◽

Manufacturing Industry ◽

Metal Cutting ◽

Deformation Behaviour ◽

Orthogonal Cutting ◽

Constitutive Models ◽

Shear Zones ◽

Cutting Processes ◽

Mechanical Cutting

Machining of metals is an essential operation in the manufacturing industry. Chip formation in metal cutting is associated with large plastic strains, large deformations, high strain rates and high temperatures, mainly located in the primary and in the secondary shear zones. During the last decades, there has been significant progress in numerical methods and constitutive modeling for machining operations. In this work, the Particle Finite Element Method (PFEM) together with a dislocation density (DD) constitutive model are introduced to simulate the machining of Ti-6Al-4V. The work includes a study of two constitutive models for the titanium material, the physically based plasticity DD model and the phenomenology based Johnson–Cook model. Both constitutive models were implemented into an in-house PFEM software and setup to simulate deformation behaviour of titanium Ti6Al4V during an orthogonal cutting process. Validation show that numerical and experimental results are in agreement for different cutting speeds and feeds. The dislocation density model, although it needs more thorough calibration, shows an excellent match with the results. This paper shows that the combination of PFEM together with a dislocation density constitutive model is an excellent candidate for future numerical simulations of mechanical cutting.

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Influence of Constitutive Models and the Choice of the Parameters on FE Simulation of Ti6Al4V Orthogonal Cutting Process for Different Uncut Chip Thicknesses

Journal of Manufacturing and Materials Processing ◽

10.3390/jmmp5020056 ◽

2021 ◽

Vol 5 (2) ◽

pp. 56

Author(s):

Nithyaraaj Kugalur Palanisamy ◽

Edouard RiviÈre LorphÈvre ◽

Pedro-José Arrazola ◽

François Ducobu

Keyword(s):

Constitutive Model ◽

Orthogonal Cutting ◽

Constitutive Models ◽

Chip Thickness ◽

Material Model ◽

Machining Process ◽

Uncut Chip Thickness ◽

Dependent Strain ◽

Important Input

The constitutive model and its pertinent set of parameters are important input data in finite element modeling to define the behavior of Ti6Al4V during machining process. The present work focusses on comparing different constitutive models and the parameters sets available in literatures and investigating the quality of the predictions when varying uncut chip thickness (40 µm, 60 µm, 100 µm and 280 µm). In addition, temperature-dependent strain hardening factor along with strain softening phenomenon based reconstructed material model is proposed. The results from the numerical simulations are compared with experimental results available in literature. The comparison shows that the force values are highly influenced by constitutive models and the choice of parameters sets, whereas the chip morphologies are mainly influenced by the uncut chip thickness and constitutive models. This work justifies the need for an appropriate set of parameters and constitutive model that replicate the machining behavior of Ti6Al4V alloy for different cutting conditions.

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JOHNSON–COOK MODEL COMBINED WITH COWPER–SYMONDS MODEL FOR BONE CUTTING SIMULATION WITH EXPERIMENTAL VALIDATION

Journal of Mechanics in Medicine and Biology ◽

10.1142/s021951942150010x ◽

2021 ◽

Vol 21 (02) ◽

pp. 2150010

Author(s):

VARATHARAJAN PRASANNAVENKADESAN ◽

PONNUSAMY PANDITHEVAN

Keyword(s):

Cutting Force ◽

Constitutive Models ◽

Percentage Error ◽

Bovine Bone ◽

Strain Rates ◽

Combined Model ◽

Cutting Simulation ◽

Lack Of Information ◽

Experimental Cutting ◽

Cook Model

Constitutive models are widely used to predict the mechanical behavior of different kinds of materials. Although the Johnson–Cook model for bovine bone and Cowper–Symonds model for human thoracic rib and tibia was developed, the predictability of these models was found good only at particular strain rates. This study addresses this lack of information by investigating the Cowper–Symonds model, Johnson–Cook model, and Johnson–Cook model combined with Cowper–Symonds model at different strain rates to utilize in the bone cutting simulation. Specimens prepared using two rear femurs harvested from a 3.50-year-old bovine were investigated at different strain rates (0.00001–1/s). A comparative study made among the stresses predicted from these models showed 29.41%, 10.91%, and 11.11% mean absolute percentage errors using Cowper–Symonds model, and 2.03%, 7.19%, and 3.62% mean absolute percentage errors using Johnson–Cook model, respectively, at 0.0001, 0.001 and 1/s strain rates. However, the Johnson–Cook model combined with the Cowper–Symonds model predicted the stress with a maximum of only 2.03% mean absolute percentage error. The potential of each model to utilize in the orthogonal bone cutting was also evaluated using Ansys® and found that the combined model predicted the cutting force close to experimental cutting force with minimal error (5.20%). The outcomes of this study can be used in the surgical practice and osteotomy procedure before commencing actual surgery.

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