New Perspectives Regarding the Chip Formation Process of Ti-6Al-4V

2021 ◽  
Author(s):  
Wolfgang Lortz ◽  
Radu Pavel
Keyword(s):  
High Temperatures ◽  
Formation Process ◽  
Chip Formation ◽  
Morphological Characteristics ◽  
Small Deformation ◽  
No Oxidation ◽  
Experimental Result ◽  
Deformation Pattern ◽  
Transversal Section ◽  
Stop Test

Abstract The mathematical, physical and morphological characteristics of the chip formation process during cutting of Ti-6Al-4V will be analyzed and presented in this paper. In recent years titanium has received more attention due to their unique material properties, such as light weight by height strength, small deformation at high temperatures, low brittleness at low temperatures, and nearly no oxidation at high temperatures, but with the disadvantage that it is difficult to machine. A lot of investigations have been conducted to solve the complex process of machining. But the real complex phenomena at the cutting edge can’t be explained with the help of simplified models. This paper presents a new mathematical-physical model describing the process mechanics leveraging two kinds of friction to explain the metal behavior to strain and stress with self-hardening or softening effects, and the dynamic chip formation behavior due to strain rate discontinuity. All these influencing parameters have an interdependent relationship; thus, they cannot be analyzed separately. The resultant deformation process leads to a grid deformation pattern in the relevant region of the transversal section of a chip that can be used for comparing the theoretical solution with the experimental result. This deformation pattern is the only characteristic that will not disappear after machining. As long as the theoretical results are found to be in agreement with the experimental data of the produced segmented chip, we can be sure, that the models integrating the friction conditions, strain-stress, and metallurgical conditions are correctly developed. In approaching these problems, it is difficult to choose the relevant machining conditions, because a “quick-stop” test is difficult to produce. The reason might be the existing contact conditions at the tool-chip interface, which has an intensive connection due to the diffusion process. Therefore, two different cutting velocities were chosen with the hope that the diffusion is not too intensive; (one slow velocity with vc = 12.5 m/min and a higher velocity with vc = 100 m/min). In addition, a photomicrograph of a chip was taken for the validation process between theoretical and experimental results. Furthermore, the existing temperatures in the contacting zone as well as in the chip formation area could be developed and are discussed and presented in this paper.

Modeling and numerical simulation of the chip formation process when machining Nomex

2021 ◽  
Author(s):  
Tarik Zarrouk ◽  
Jamal-Eddine Salhi ◽  
Samir Atlati ◽  
Mohammed Nouari ◽  
Merzouki Salhi ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Formation Process ◽  
Chip Formation

Digital twin of the chip formation process

2020 ◽  
pp. 81-86
Author(s):  
Yu.G. Kabaldin ◽  
D.A. Shatagin ◽  
M.S. Anosov ◽  
A.M. Kuz'mishina
Keyword(s):  
Neural Network ◽  
Control System ◽  
Crystal Lattice ◽  
Network Model ◽  
Intelligent Control ◽  
Neural Network Model ◽  
Formation Process ◽  
Chip Formation ◽  
Intelligent Control System ◽  
The Relationship

The formation of chips during the processing of various materials was studied. The relationship between the type of chips, the type of crystal lattice of the material and the number of sliding systems is shown. A neural network model of chip formation is developed, which allows predicting the type of chips. An intelligent control system for the process of chip formation during cutting is proposed. Keywords: chip formation, crystal lattice, neural network model, type of chips. [email protected]

Investigation on the Elemental Chip Formation Process in Hard-to-Machine Material Cutting

2014 ◽  
Vol 682 ◽  
pp. 504-509 ◽  
Author(s):  
A.A. Lasukov ◽  
P.A. Chazov ◽  
А.V. Barsuk
Keyword(s):  
Mechanical Properties ◽  
Formation Process ◽  
Chip Formation ◽  
Physical And Mechanical Properties ◽  
Cutting Process ◽  
Machine Material ◽  
Continuous Chip ◽  
Material Cutting

The mechanism of discontinuous chip formation has been studied less than the mechanism of continuous chip formation. However, when most modern materials having specific physical and mechanical properties are subject to machining, such processes are featured by discontinuous chip formation. The paper describes the basic dependencies of discontinuous chip parameters on machining modes. This is a trial undertaken to introduce an explanation of how the basic factors of the cutting process influence over parameters of chip formation.

scholarly journals Simulation of plastic deformation and destruction in the process of chip formation

2018 ◽  
Vol 211 ◽  
pp. 17007
Author(s):  
Tanel Tärgla ◽  
Jüri Olt ◽  
Olga Liivapuu
Keyword(s):  
Plastic Deformation ◽  
Formation Process ◽  
Chip Formation ◽  
Rheological Model ◽  
Metal Cutting ◽  
Depth Of Cut ◽  
Key Factors ◽  
Local Zone ◽  
Complex Process ◽  
Relaxing Medium

Metal cutting is a complex process in which several mechanisms are at work simultaneously. The mathematical modelling allows carrying out research into the optimization of machining conditions. This work examines the simulation of chip formation during the process of cutting. The studies demonstrated that the chip formation process, taking into account the plastic deformation and destruction of metal in the local zone, is most appropriately represented by a rheological model in the form of a series connection of elasticductile- plastic relaxing medium of Ishlinskiy (reflecting the process of primary deformation of metal from the cut off layer) and the medium of Voigt with two elastic-dissipative elements (representing the process of deformation and frictions from the convergent shaving). The attained complex rheological model served as the basis for constructing a representative dynamic model for the chip formation process. The key factors that govern the chip formation have been taken into account, such as tool vibration frequency and amplitude, depth of cut, feed rate.

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.

The Realities of Friction in Metal Plastic Flow With Corresponding Results During Metal Cutting

2019 ◽  
Author(s):  
Wolfgang Lortz ◽  
Radu Pavel
Keyword(s):  
Internal Friction ◽  
Strain Rate ◽  
Plastic Flow ◽  
Cross Sections ◽  
Chip Formation ◽  
Metal Cutting ◽  
Material Behavior ◽  
Deformation Pattern ◽  
Low Velocity ◽  
As Stress

Abstract Metal cutting is a dynamic process with two types of friction: on the one hand, external friction between two different bodies, and on the other hand, an internal friction inside the same material, due to plastic flow. These two different types of friction lead to different chip formation processes. In the case of built-up-edge (BUE), low velocity creates low energy, resulting in a self-hardening effect with BUE. With increasing velocity, the energy will increase and will result in high temperatures with a built-up-layer (BUL). Furthermore, under special circumstances, friction will lead to a self-blockade (a self-blocking state). This situation describes the third stage in metal plastic flow — the creation of a segmental chip. In this case the internal friction takes over. One question arises: “How can we determine these two types of different friction?” For solving these phenomena new fundamental equations based on mathematics, physics and material behavior have to be developed. This paper presents newly developed equations, which deliver the theoretical distribution of yield shear stress as well as strain rate with corresponding grid deformation pattern in metal plastic flow. For an actual cut, the plastic deformation pattern remains when the process is stopped, and therefore the theoretical result can be compared with cross-sections of the relevant chip formation areas — contrary to outputs such as stress, strain rate and temperatures which are all functions of position and time. All this will be shown and discussed in the paper, and stands in good agreement with experimental results.

Flow Instability in the Orthogonal Machining of CP Titanium

1997 ◽  
Vol 119 (3) ◽  
pp. 307-313 ◽  
Author(s):  
J. Sheikh-Ahmad ◽  
J. A. Bailey
Keyword(s):  
Shear Strain ◽  
Formation Process ◽  
Chip Formation ◽  
Flow Instability ◽  
Pure Titanium ◽  
Plastic Instability ◽  
Shear Localization ◽  
Instability Criterion ◽  
Commercially Pure Titanium ◽  
Orthogonal Machining

An experimental and analytical investigation of flow instability and shear localization in the orthogonal machining of grade 2 commercially pure titanium was made. A criterion for thermo-plastic instability was developed from torsion test results and applied to the analysis of the chip formation process. It was shown that flow instability followed by flow localization occurs when machining titanium at all cutting speeds and that a transition in the chip type from uniform to segmented does not occur. Orthogonal machining experiments were conducted in the speed range from 8.75 × 10−5 to 3.20 m/s for various depths of cut and the shear strain in the chip was calculated. It was shown that shear localization occurred in the chip formation process when the uniform shear strain involved in producing a chip segment reached a critical value and that this critical shear strain correlates fairly well with the instability shear strain predicted by the thermo-plastic instability criterion.

scholarly journals Research the chip formation process thermoplastic turning

2020 ◽  
pp. 46-48
Author(s):  
O. YU. Erenkov
Keyword(s):  
Formation Process ◽  
Chip Formation ◽  
Experimental Studies ◽  
Polymer Materials ◽  
Cutting Depth ◽  
The Relationship ◽  
Cutting Modes

The article presents the results of experimental studies of the relationship between the characteristics of cutting modes and nature of chip formation for thermoplastics blanks. Caprolon and fl uoroplast-4 were used as the studied materials. It has been experimentally proved that the cutting depth has the maximum eff ect on the chip formation character when turning blanks from the studied polymer materials.

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