Imaging and analysis of chip formation during orthogonal cutting of titanium alloy Ti-6Al-4V

2007 ◽  
Vol 1 (1) ◽  
pp. 65 ◽  
Author(s):  
Matthew Cotterell ◽  
Gerry Byrne
Keyword(s):  
Titanium Alloy ◽  
Chip Formation ◽  
Orthogonal Cutting

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.

On Methodologies inside Two Different Commercial Codes to Simulate the Cutting Operation

2011 ◽  
Vol 223 ◽  
pp. 162-171
Author(s):  
Yan Cheng Zhang ◽  
Domenico Umbrello ◽  
Tarek Mabrouki ◽  
Stefania Rizzuti ◽  
Daniel Nelias ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Titanium Alloy ◽  
Surface Integrity ◽  
Chip Formation ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Cutting Parameters ◽  
Cutting Operation ◽  
Cutting Processes ◽  
Cutting Model

Nowadays, numerical simulation of cutting processes receives considerable interest among the scientific and industrial communities. For that, various numerical codes are used. Nevertheless, there is no uniform standard for the comparison of simulation model with these different software. So, it is often not easy to state if a given code is more pertinent than another. In this framework, the present work deals with various methodologies to simulate orthogonal cutting operation inside two commercial codes Abaqus and Deform. The aim of the present paper is to build a common benchmark model between the two pre-cited codes which can initiate other numerical cutting model comparisons. The study is focused on the typical aeronautical material - Ti-6Al-4V - Titanium alloy. In order to carry out a comparative study between the two codes, some similar conditions concerning geometrical models and cutting parameters were respected. A multi-physic comprehension related to chip formation, cutting forces and temperature evolutions, and surface integrity is presented. Moreover, the numerical results are compared with experimental ones.

Chip Formation and Cutting Performance Investigation on Titanium Alloy Machining

2011 ◽  
Vol 264-265 ◽  
pp. 1062-1072
Author(s):  
Shen Yung Lin ◽  
Y.Y. Cheng ◽  
C.T. Chung
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Chip Formation ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Cutting Performance ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Chip Type ◽  
Cutting Model

First, a 2D orthogonal cutting model for titanium alloy is constructed by finite element method in this study. The cutting tool is incrementally advanced forward from an incipient stage of tool-workpiece engagement to a steady state of chip formation. Cockroft and Latham fracture criterion [1] is adopted as a chip separation criterion. By changing the settings of cutting variables such as cutting speed, depth of cut and tool rake angle to investigate the chip formation process and the variation of cutting performance during titanium cutting simulation. The changes of chip type, cutting force, effective stress/strain and cutting temperature with different cutting condition combinations are thus analyzed. The result demonstrates that the serrated chip type is obviously produced when cutting titanium alloy. Next, water-based and oil-based cutting fluids are employed in conjunction with proper cutting parameter arrangements to perform up-milling experiments. By measuring the cutting force, surface roughness and tool wear to investigate the effect of these combinations of milling variables on the variation of cutting performance for Ti-6Al-4V. The chip shape and cutting force obtained from the experiment are compared with those calculated from simulation. It is shown that there is a good agreement between simulation and experimental results.

scholarly journals Towards Dry Machining of Titanium-Based Alloys: A New Approach Using an Oxygen-Free Environment

Metals ◽  
2020 ◽  
Vol 10 (9) ◽  
pp. 1161
Author(s):  
Hans Jürgen Maier ◽  
Sebastian Herbst ◽  
Berend Denkena ◽  
Marc-André Dittrich ◽  
Florian Schaper ◽  
...  
Keyword(s):  
Titanium Alloy ◽  
Wear Mechanism ◽  
Chip Formation ◽  
Cutting Forces ◽  
High Vacuum ◽  
Argon Atmosphere ◽  
Dry Machining ◽  
New Approach ◽  
Underlying Mechanisms ◽  
Free Environment

In the current study, the potential of dry machining of the titanium alloy Ti-6Al-4V with uncoated tungsten carbide solid endmills was explored. It is demonstrated that tribo-oxidation is the dominant wear mechanism, which can be suppressed by milling in an extreme high vacuum adequate (XHV) environment. The latter was realized by using a silane-doped argon atmosphere. In the XHV environment, titanium adhesion on the tool was substantially less pronounced as compared to reference machining experiments conducted in air. This goes hand in hand with lower cutting forces in the XHV environment and corresponding changes in chip formation. The underlying mechanisms and the ramifications with respect to application of this approach to dry machining of other metals are discussed.

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