Analysis of flat-end milling forces considering chip formation process in high-speed cutting of Ti6Al4V titanium alloy

2020 ◽  
Vol 100 ◽  
pp. 102039 ◽  
Author(s):  
Mehmet Aydın ◽  
Uğur Köklü
Keyword(s):  
Titanium Alloy ◽  
Formation Process ◽  
Chip Formation ◽  
High Speed ◽  
End Milling ◽  
High Speed Cutting ◽  
Ti6al4v Titanium Alloy ◽  
Flat End Milling ◽  
Milling Forces

Finite Element Analysis on Segmented Chip Formation for High Speed Cutting of Ti6Al4V Alloy

2009 ◽  
Vol 407-408 ◽  
pp. 599-603
Author(s):  
Xiang Hua Zhang ◽  
Hong Bing Wu
Keyword(s):  
Finite Element ◽  
Titanium Alloy ◽  
Finite Element Model ◽  
Chip Formation ◽  
High Speed ◽  
Element Model ◽  
High Speed Cutting ◽  
Segmented Chip ◽  
Titanium Alloy Ti6al4v ◽  
The Finite Element Model

To accurately simulate the segmented chip formation of titanium alloy Ti6Al4V in high speed cutting process, the key techniques of the finite element modeling were investigated detailed, which included establishing the finite element model, material constitutive relation, chip separation criteria, material failure criteria. A high speed cutting case of titanium alloy Ti6Al4V were simulated with thermal mechanical analysis and adiabatic analysis respectively. Through the comparison of the two simulated results, it proved the segmented chip is formed because of the adiabatic shear. The results prove the finite element model established is correct.

Experimental investigation of top burr formation in high-speed micro-end milling of titanium alloy

2018 ◽  
Vol 22 (6) ◽  
pp. 989-1011 ◽  
Author(s):  
Chakradhar Bandapalli ◽  
Kundan Kumar Singh ◽  
Bharatkumar Mohanbhai Sutaria ◽  
Dhananjay Vishnuprasad Bhatt
Keyword(s):  
Experimental Investigation ◽  
Titanium Alloy ◽  
High Speed ◽  
End Milling ◽  
Burr Formation ◽  
Micro End Milling

scholarly journals Mechanism of Chip Formation Process at Grinding

2019 ◽  
Vol 297 ◽  
pp. 09002
Author(s):  
Vyacheslav Shumyacher ◽  
Sergey Kryukov ◽  
Olga Kulik ◽  
Xavier Kennedy
Keyword(s):  
Formation Process ◽  
Chip Formation ◽  
High Speed ◽  
Cutting Speed ◽  
Dimensional Accuracy ◽  
Processing Parameters ◽  
Abrasive Grain ◽  
Wave Heating ◽  
High Speed Grinding

The mechanism of chip formation process at grinding is described, which involves a high-speed interaction of abrasive grain and metal, which leads to a concentration of thermal energy in front of the dispersing element (grain), causing a locally concentrated shift in the metal microvolume. In “abrasive grain -metal” contact a dissipative structure is formed which existence is supported by exchange of energy and substance with environment. Due to shock compression of the metal microvolume with abrasive grain, shock-wave heating is realized, initiating emission of electrons ionizing the lubricating cooling fluid in the zone of formation of side micro-scratches left by abrasive. The results obtained in the course of the research can be used to explain the mechanisms of chip formation, as well as the course of the physical and mechanical processes occurring on the surface layers of the grinded workpieces. By controlling chip formation processes at high-speed grinding, by optimally selecting the appropriate ratios between cutting speed and other processing parameters, a reduction in process thermal density can be achieved, which, with the highest productivity, will allow to obtain the required quality of the surface layer of the workpieces and a given dimensional accuracy.

An Experiment-Based Investigation on Characteristic and Model of Milling Forces during End-Milling Aluminum Alloy

2014 ◽  
Vol 494-495 ◽  
pp. 602-605
Author(s):  
Zeng Hui An ◽  
Xiu Li Fu ◽  
Ya Nan Pan ◽  
Ai Jun Tang
Keyword(s):  
Aluminum Alloy ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Metal Cutting ◽  
End Milling ◽  
Influence Factors ◽  
Cutting Speed ◽  
Cutting Depth ◽  
Milling Forces

Cutting forces is one of the important physical phenomena in metal cutting process. It directly affects the surface quality of machining, tool life and cutting stability. The orthogonal experiments of cutting forces and influence factors with indexable and solid end mill were accomplished and the predictive model of milling force was established during high speed end milling 7050-T7451 aluminum alloy. The paper makes research mainly on the influence which the cutting speed, cutting depth and feed have on the cutting force. The experimental results of single factor showed that the cutting forces increase earlier and drop later with the increase of cutting speed, and the cutting speed of inflexion for 7050-T7451 is 1100m/min. As axial cutting depth, radial cutting depth and feed rate increase, the cutting force grows in different degree. The cutting force is particularly sensitive to axial cutting depth and slightly to the radial cutting depth.

Experimental Study on Micro End-Milling Process of Ti-6AL-4V Using Nanofluid Minimum Quantity Lubrication (MQL)

2014 ◽  
Author(s):  
Dae Hoon Kim ◽  
Pil-Ho Lee ◽  
Jung Sub Kim ◽  
Hyungpil Moon ◽  
Sang Won Lee
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
End Milling ◽  
Minimum Quantity Lubrication ◽  
Milling Process ◽  
Minimum Quantity ◽  
Nanofluid Minimum Quantity Lubrication ◽  
Micro End Milling ◽  
Milling Forces ◽  
End Milling Process

This paper investigates the characteristics of micro end-milling process of titanium alloy (Ti-6AL-4V) using nanofluid minimum quantity lubrication (MQL). A series of micro end-milling experiments are conducted in the meso-scale machine tool system, and milling forces, burr formations, surface roughness, and tool wear are observed and analyzed according to varying feed per tooth and lubrication conditions. The experimental results show that MQL and nanofluid MQL with nanodiamond particles can be effective to reduce milling forces, burrs and surface roughness during micro end-milling of titanium alloy. In particular, it is demonstrated that smaller size of nanodiamond particles — 35 nm — can be more effective to decrease burrs and surface roughness in the case of nanofluid MQL micro end-milling.

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