Thermal-Mechanical Responses of Ti-6Al-4V during Orthogonal Cutting Process

2008 ◽  
pp. 673-678
Author(s):  
Mohd N. Tamin ◽  
Izman Sudin ◽  
Thet T. Mon
Keyword(s):  
Orthogonal Cutting ◽  
Cutting Process ◽  
Mechanical Responses

Thermal-Mechanical Responses of Ti-6Al-4V during Orthogonal Cutting Process

2008 ◽  
Vol 273-276 ◽  
pp. 673-678 ◽  
Author(s):  
Mohd Nasir Tamin ◽  
Sudin Izman ◽  
Thet Thet Mon
Keyword(s):  
Shear Band ◽  
Diamond Tool ◽  
Orthogonal Cutting ◽  
Cvd Diamond ◽  
Cutting Edge ◽  
Cutting Process ◽  
Cutting Condition ◽  
Workpiece Material ◽  
Stick Slip ◽  
Mechanical Responses

Orthogonal metal cutting process involves large plastic deformation accompanied by excessive heat generation. This work addresses the thermal-mechanical responses of the workpiece material at the tool-workpiece contact. In this respect, the orthogonal cutting process of Ti-6Al-4V using CVD diamond tool is simulated using finite element method. The cutting condition consists of cutting speed, V=180 m/min, feed rate, t=0.125 mm/rev and width of cut of 1.25 mm. Eulerian formulation with coupled thermal-mechanical analysis is employed in the model. The Johnson- Cook constitutive equation is employed for Ti-6Al-4V workpiece material to accurately simulate the formation of shear bands. The stick-slip friction condition is modeled at the tool-chip interface. The sliding coefficient of friction of 0.8 and the limiting shear stress of 700 MPa for stick-slip condition are determined experimentally. Results show that high temperature and temperature gradient concentrate in the primary shear zone and the contact area between the tool rake face and the chip. A primary shear band is predicted in the workpiece ahead of the tool-workpiece contact face while the secondary shear band is formed in the chip. This highly-deformed shear band is revealed in the microstructure of etched chips. The predicted high strain rate results in build-up edge at tool cutting edge-chip contact. Low cutting condition of V=150 m/min, t=0.125 mm/rev promotes stagnant zone formation that helps preserve the cutting edge of the tool. The maximum predicted temperature at the cutting edge is in excess of 700 °C. Such high temperature level facilitates diffusion of carbon elements into the chips and conversely, elements of titanium into the CVD diamond tool.

Using Image Analysis Techniques for Single Evaluation of the Chip Shrinkage Factor in Orthogonal Cutting Process

2012 ◽  
Vol 504-506 ◽  
pp. 1329-1334 ◽  
Author(s):  
Moises Batista ◽  
Madalina Calamaz ◽  
Franck Girot ◽  
Jorge Salguero ◽  
Mariano Marcos
Keyword(s):  
High Speed ◽  
Orthogonal Cutting ◽  
Rake Angle ◽  
Cutting Process ◽  
Shrinkage Factor ◽  
A Value ◽  
Chip Shrinkage ◽  
Chip Geometry ◽  
Image Analysis Techniques

The forces involved in a cutting process are related, for example, with the power consumption, with the final quality of the workpiece and with the chip geometry obtained, since these forces determine the compression experimented by the chip and therefore its final geometry. The orthogonal cutting process assisted with a High Speed Filmation (HSF) permit obtains a digital filmation of the process with high magnification. This filmation permits to obtain a measurement of the longitudinal changes produced in the chip. This deforms are related with the Shrinkage Factor, ζ. And in this case the Stabler hypothesis is enabled, by that using the shear angle and the rake angle is possible obtain a value of the Shrinkage Factor in a different conditions.

Simulation of Chip Formation in an Orthogonal Cutting Process Using Fem

2002 ◽  
pp. 167-177 ◽  
Author(s):  
G. Giorleo ◽  
R. Teti ◽  
A. Langella ◽  
D. D’Addona ◽  
U. Prisco
Keyword(s):  
Chip Formation ◽  
Orthogonal Cutting ◽  
Cutting Process

Determination of Inner and Outer Modulation Dynamics in Orthogonal Cutting

1987 ◽  
Vol 109 (4) ◽  
pp. 275-280 ◽  
Author(s):  
T. Y. Ahn ◽  
K. F. Eman ◽  
S. M. Wu
Keyword(s):  
Orthogonal Cutting ◽  
Theoretical Background ◽  
Cutting Process ◽  
Experimental Realization ◽  
Process Dynamics ◽  
Orthogonal Turning ◽  
Machine Tool Structure ◽  
Dynamic Cutting Force ◽  
Experimental Errors ◽  
Modeling Strategy

Many efforts have been devoted in the past to the identification of the dynamic behavior of the cutting process. Nevertheless, there have been no consistent results due to the inherent complexity of the cutting process, and the methodological and experimental errors involved. Among the problems to be solved, the experimental realization of the double modulation is the most difficult one. Present approaches use elaborate instrumentation and assume the delayed inner modulation for the outer modulation. This assumption may not hold under all circumstances and it will be modified in this paper. The present method approaches the cutting process as a one-input one-output process consisting of the inner modulation and dynamic cutting force component. The application of bivariate time series models give the transfer function of the inner modulation dynamics. The outer modulation dynamics’ effect on the cutting process is subsequently determined from the disturbance noise dynamics. The theoretical background for the proposed approach along with a new modeling strategy has been introduced in detail. The experimental verification of the theoretical postulates and the identification of the cutting process dynamics were carried out using actual data collected from an orthogonal turning process of a tubular workpiece. External white noise excitation was used and the experimental setup was designed to minimize the errors caused by inertia and disturbances. Although the proposed method requires prior knowledge of the machine tool structure, it requires a comparatively simple experimental procedure and minimizes the possible errors associated with the signal processing task.

Numerical Simulation of Metal Cutting Process Based on ANSYS/LS-DYNA

2015 ◽  
Vol 727-728 ◽  
pp. 335-338 ◽  
Author(s):  
Song Jie Yu ◽  
Di Di Wang ◽  
Xin Chen
Keyword(s):  
Cutting Force ◽  
Metal Cutting ◽  
Plastic Material ◽  
Orthogonal Cutting ◽  
Cutting Process ◽  
Machining Process ◽  
Linear Deformation ◽  
Deformation Problem ◽  
Non Linear ◽  
Elastic Plastic Material

Cutting process is a typical non-linear deformation problem, which involves material non-linear, geometry non-linear and the state non-linear problem. Based on the elastic-plastic material deformation theory, this theme established a strain hardening model. Build the simulation model of two-dimensional orthogonal cutting process of workpiece and tool by the finite element method (FEM), and simulate the changes of cutting force and the process of chip formation in the machining process, and analyzed the cutting force, the situation of chip deformation. The method is more efficient and effective than the traditional one, and provides a new way for metal cutting theory, research of material cutting performance and cutting tool product development.

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