Three-Dimensional Finite Element Analysis in Cutting Temperature for High Speed Milling of Titanium Alloys

2011 ◽  
Vol 189-193 ◽  
pp. 2259-2263
Author(s):  
You Xi Lin ◽  
Cong Ming Yan
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Titanium Alloys ◽  
High Speed ◽  
Three Dimensional ◽  
Cutting Temperature ◽  
Maximum Temperature ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

A three dimensional fully thermal-mechanical coupled finite element model had been presented to simulate and analyze the cutting temperature for high speed milling of TiAl6V4 titanium alloy. The temperature distribution induced in the tool and the workpiece was predicted. The effects of the milling speed and radial depth of cut on the maximum cutting temperature in the tool was investigated. The results show that only a rising of temperature in the lamella of the machined surface is influenced by the milling heat. The maximum temperature in the tool increases with increasing radial depth of cut and milling speed which value is 310°C at a speed of 60 m/min and increases to 740°C at 400m/min. The maximum temperature is only effective on a concentrated area at the cutting edge and the location of the maximum temperature moves away from the tool tip for higher radial depths of milling. The predicted temperature distribution during the cutting process is consistent with the experimental results given in the literature. The results obtained from this study provide a fundamental understanding the process mechanics of HSM of titanium alloys.

FEM Analysis of Temperature in High Speed Cutting of TiAl6V4 Alloys

2012 ◽  
Vol 522 ◽  
pp. 201-205
Author(s):  
You Xi Lin ◽  
Cong Ming Yan ◽  
Zheng Ying Lin
Keyword(s):  
Temperature Distribution ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Fem Analysis ◽  
Element Model ◽  
Maximum Temperature ◽  
Depth Of Cut ◽  
Machined Surface ◽  
Radial Depth

mprovements in modeling and simulation of metal cutting processes are required in advanced manufacturing technologies. A three dimensional fully thermal mechanical coupled finite element model had been applied to simulate and analyze the cutting temperature for high speed milling of TiAl6V4 titanium alloy. The temperature distribution induced in the tool and the workpiece was predicted. The effects of the milling speed and radial depth of cut on the maximum cutting temperature in the tool was investigated. The results show that only a rising of temperature in the lamella of the machined surface is influenced by the milling heat. The maximum temperature in the tool increases with increasing radial depth of cut and milling speed which value is 310°C at a speed of 60 m/min and increases to 740°C at 400m/min. The maximum temperature is only effective on a concentrated area at the cutting edge and the location of the maximum temperature moves away from the tool tip for higher radial depths of milling. The predicted temperature distribution during the cutting process is consistent with the experimental results given in the literature. The results obtained from this study provide a fundamental understanding the process mechanics of HSM of TiAl6V4 titanium alloys.

Cutting Temperature and Cutting Forces Investigation Based on the Taguchi Design Method when High-Speed Milling of Titanium Matrix Composites with PCD Tool

2016 ◽  
Vol 836-837 ◽  
pp. 168-174 ◽  
Author(s):  
Ying Fei Ge ◽  
Hai Xiang Huan ◽  
Jiu Hua Xu
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Volume Fraction ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth

High-speed milling tests were performed on vol. (5%-8%) TiCp/TC4 composite in the speed range of 50-250 m/min using PCD tools to nvestigate the cutting temperature and the cutting forces. The results showed that radial depth of cut and cutting speed were the two significant influences that affected the cutting forces based on the Taguchi prediction. Increasing radial depth of cut and feed rate will increase the cutting force while increasing cutting speed will decrease the cutting force. Cutting force increased less than 5% when the reinforcement volume fraction in the composites increased from 0% to 8%. Radial depth of cut was the only significant influence factor on the cutting temperature. Cutting temperature increased with the increasing radial depth of cut, feed rate or cutting speed. The cutting temperature for the titanium composites was 40-90 °C higher than that for the TC4 matrix. However, the cutting temperature decreased by 4% when the reinforcement's volume fraction increased from 5% to 8%.

Cutting Temperature Investigation when High-Speed Milling of SiCP/Al Composites

2011 ◽  
Vol 697-698 ◽  
pp. 198-203
Author(s):  
Ying Fei Ge ◽  
Jiu Hua Xu ◽  
Yu Can Fu
Keyword(s):  
High Speed ◽  
Volume Fraction ◽  
Influence Factors ◽  
Cutting Temperature ◽  
Depth Of Cut ◽  
Minor Effect ◽  
High Speed Milling ◽  
Tool Materials ◽  
Radial Depth ◽  
Pcd Tools

High-speed milling tests were performed on SiCp/2009Al composites in the speed range of 600-1200m/min using PCD tools to investigate the cutting temperatures and the influence factors. The results showed that the cutting temperature could reach 580°C under the given cutting conditions. Graphitization took place on the PCD tools under the high cutting temperature coupled with the effects of abrasive wear of SiC particles and catalysis of copper in the 2009 aluminum matrix. Cutting parameters, tool materials, workpiece materials and tool wear condition had significant effect on the high speed milling temperature while tool geometries had the minor effect. Among these influence factors, cutting speed was the most significant factor. Reinforcement volume fraction was the less significant factor and followed by radial depth of cut, feed rate and tool materials.

Experimental Studies on Cutting Temperature of Nickel-Based Supper Alloy Inconel 718

2013 ◽  
Vol 584 ◽  
pp. 20-23
Author(s):  
Mao Hua Xiao ◽  
Ning He ◽  
Liang Li ◽  
Xiu Qing Fu
Keyword(s):  
Inconel 718 ◽  
High Speed ◽  
Experimental Studies ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth ◽  
The Impact

The method to measure the cutting speed when high speed milling nickel alloy Inconel 718 based on semi-artificial thermocouple. The cutting parameters, tool wear and so on the cutting temperature were analyzed. The tests showed that the temperature was gradually increased with the increase of cutting speed. The cutting speed must be more than 600m/min, when the ceramic tools would perform better cutting performance in the high-speed milling nickel-based superalloy. In order to achieve more efficient machining, milling speed can be increased to more than 1000m/min. The impact amount of Radial depth of cut and feed per tooth were relatively small.

scholarly journals Finite element analysis and modeling of temperature distribution in turning of titanium alloys

10.30544/323 ◽  
2018 ◽  
Vol 24 (1) ◽  
pp. 59-69 ◽  
Author(s):  
Moola Mohan Reddy ◽  
Mohan Kumar ◽  
Kumaraesan Shanmugam
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Titanium Alloys ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Surface Model ◽  
Element Analysis

The titanium alloys (Ti-6Al-4V) have been widely used in aerospace, and medical applications and the demand is ever-growing due to its outstanding properties. In this paper, the finite element modeling on machinability of Ti-6Al-4V using cubic boron nitride and polycrystalline diamond tool in dry turning environment was investigated. This research was carried out to generate mathematical models at 95% confidence level for cutting force and temperature distribution regarding cutting speed, feed rate and depth of cut. The Box-Behnken design of experiment was used as Response Surface Model to generate combinations of cutting variables for modeling. Then, finite element simulation was performed using AdvantEdge®. The influence of each cutting parameters on the cutting responses was investigated using Analysis of Variance. The analysis shows that depth of cut is the most influential parameter on resultant cutting force whereas feed rate is the most influential parameter on cutting temperature. Also, the effect of the cutting-edge radius was investigated for both tools. This research would help to maximize the tool life and to improve surface finish.

Thermal–mechanical coupled finite element analysis of aluminum alloy grid sheet in high-speed milling

2016 ◽  
Vol 231 (3) ◽  
pp. 389-398
Author(s):  
Zhao Liu ◽  
Weiping Peng ◽  
Lijie Guo ◽  
Fengbo Dong ◽  
Jiangwei Ma
Keyword(s):  
Finite Element ◽  
Calculation Method ◽  
High Speed ◽  
Tool Path ◽  
Mechanical Load ◽  
Depth Of Cut ◽  
Processing Scheme ◽  
High Speed Milling ◽  
Radial Depth ◽  
Load Calculation

Because of notable distortion in high-speed milling of grid sheet, it is difficult to choose a feasible processing scheme for this kind of workpiece. This article attempts to present a method to analyze the stress and deformation of grid sheet under different processing schemes based on a coupled mechanical–thermal finite element model, which provides a convenient and flexible platform to evaluate the performance of processing scheme in high-speed milling and optimize the cutting conditions. After a thorough analysis of the whole milling process of grid sheet, the tool path was discretized to make it convenient for the modeling of material removal process. An analytical thermal load calculation method and an experimental mechanical load calculation method were adopted to determine the loads exerted on the grid sheet. The constraint of the fixture was also considered, and finally, an ANSYS Parametric Design Language–based finite element method model was established. Based on this model, stresses and deformations under a given processing scheme with or without considering heat effect were compared, and it shows that cutting heat has great effect on the magnitude and distribution of deformation and stress. In addition, effects of some parameters on machining quality were investigated, and it was found that radial depth of cut has more impact than other parameters.

Tool Wear Characteristics in High Speed Milling of Ti-6Al-4V Alloy with Nitrogen Gas Medium

2006 ◽  
Vol 315-316 ◽  
pp. 588-592 ◽  
Author(s):  
Wei Zhao ◽  
Ning He ◽  
Liang Li ◽  
Z.L. Man
Keyword(s):  
Tool Wear ◽  
High Speed ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth ◽  
Oil Mist ◽  
Electron Microscopes ◽  
Scanning Electron Microscopes

High speed milling experiments using nitrogen-oil-mist as cutting medium were undertaken to investigate the characteristics of tool wear for Ti-6Al-4V Alloy, a kind of important and commonly used titanium alloy in the aerospace and automobile industries. Uncoated carbide tools have been applied in the experiments. The cutting speed was 300 m/min. The axial depth of cut and the radial depth of cut were kept constant at 5.0 mm and 1.0 mm, respectively. The feed per tooth was 0.1 mm/z. Optical and scanning electron microscopes have been utilized to determine the wear mechanisms of the cutting tools, and energy spectrum analysis has been carried out to measure the elements distribution at the worn areas. Meanwhile, comparisons were made to discuss the influence of different cutting media such as nitrogen-oil-mist and air-oil–mist upon the tool wear. The results of this investigation indicate that the tool life in nitrogen-oil-mist is significantly longer than that in air-oil-mist, and nitrogen-oil-mist is more suitable for high speed milling of Ti-6Al-4V alloy than air-oil-mist.

Comparative Study on Cutting Force Simulation Using DEFORM 3D Software during High Speed Machining of Ti-6Al-4V

2020 ◽  
Vol 856 ◽  
pp. 50-56
Author(s):  
Kundan Kumar Prasad ◽  
Santosh Kumar Tamang ◽  
M. Chandrasekaran
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
High Speed ◽  
Cutting Temperature ◽  
Experimental Result ◽  
Depth Of Cut ◽  
Work Piece ◽  
High Speed Machining ◽  
3D Software ◽  
Deform 3D

The finite element-based machining simulations for evaluation/computation of different machining responses (i.e., cutting temperature, tool wear, cutting force, and power/energy consumption) are investigated by number of researchers. In this work, finite element machining simulation was performed to obtain knowledge about cutting forces during machining of hard materials. Titanium alloy (Ti-6Al-4V) has been increasingly used in aerospace and biomedical applications due to high toughness and good corrosion resistance. The high speed machining (HSM) simulation of Ti-6Al-4V work-piece using carbide tool coated with TiCN has been conducted with different combination of cutting conditions for prediction of main cutting force (Fz). The simulated result obtained from Deform 3D software is validated with experimental result and it was found that the result found in good agreement. The parametric variation shows that depth of cut and feed are influencing parameters on cutting force.

Three-Dimensional Finite Element Simulation Analysis of Cutting Force of SiCp/Al Composite Thin-Walled Parts

2013 ◽  
Vol 589-590 ◽  
pp. 106-110 ◽  
Author(s):  
Yu Nan Liu ◽  
Shu Tao Huang ◽  
Li Zhou ◽  
Li Fu Xu
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Simulation Analysis ◽  
Three Dimensional ◽  
Depth Of Cut ◽  
Milling Force ◽  
Machining Deformation ◽  
Al Composite ◽  
Radial Depth ◽  
Thin Walled

In milling process, cutting force is the main cause of machining deformation, and in machining of thin-walled parts, machining deformation is the major factor for machining error. In this paper, through finite element analysis software ABAQUS, three-dimensional simulation analysis on the machining of SiCp/Al composite thin-walled parts with a polycrystalline diamond tool have been carried out. It reveals the influence of radial depth of cut, cutting speed, and feed per tooth on cutting force. Analysis results show that: higher speed, small radial depth of cut and moderate feed per tooth can effectively reduce cutting force and inhibit deformation. In addition, a comparison is made between analysis results of milling force and high accuracy milling force prediction model, results from the two methods are similar.

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