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.

Analytical Prediction of Three Dimensional Cutting Process—Part 2: Chip Formation and Cutting Force with Conventional Single-Point Tool

1978 ◽  
Vol 100 (2) ◽  
pp. 229-235 ◽  
Author(s):  
E. Usui ◽  
A. Hirota
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Single Point ◽  
Orthogonal Cutting ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Analytical Prediction ◽  
Nose Radius ◽  
Cutting Model

The cutting model and the energy method to predict chip formation and cutting force, which were proposed in the previous part of this study, are extended to machining with conventional single-point tool. The prediction is always possible in the practical range of cutting conditions regardless of size of cutting and tool geometry, if only orthogonal cutting data under equivalent cutting conditions are in hand. The predicted results are verified to be in good agreement with the experimental results in a wide variety of depth of cut, side and back rake angles, side cutting edge angle, and nose radius.

Cutting Model in Machining of Al/SiCp Metal Matrix Composite

2011 ◽  
Vol 410 ◽  
pp. 291-297
Author(s):  
Sayed Mohamad Nikouei ◽  
R. Yousefi ◽  
Mohammad Ali Kouchakzadeh ◽  
M.A. Kadivar
Keyword(s):  
Chip Formation ◽  
Cutting Forces ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Shear Plane ◽  
Good Method ◽  
Depth Of Cut ◽  
Machining Forces ◽  
Experimental Cutting ◽  
Cutting Model

Prediction of shear plane angle is a way for prediction of the mechanism of chip formation, machining forces and so on. In this study, Merchant and Lee-Shaffer theories are used for prediction of shear plane angles and cutting forces in machining of Al/SiCpMMC with 20% of SiC as reinforcement particles. The experimental cutting forces are compared with the calculated cutting force based on shear plane angles extracted from Merchant and Lee-Shaffer theories. The variation of these cutting forces with cutting speed, feed rate and depth of cut has been discussed. The results showed that Merchant theory may be used as a good method for prediction of chip formation in machining of Al/SiCpMMC.

Study on Determination of Friction Model at the Tool-Chip Interface of Titanium Alloy Ti6Al4V Based on Orthogonal Cutting

2011 ◽  
Vol 117-119 ◽  
pp. 1788-1791
Author(s):  
Yue Feng Yuan ◽  
Wu Yi Chen
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Friction Model ◽  
Carbide Tool ◽  
Orthogonal Turning ◽  
Titanium Alloy Ti6al4v

It is necessary for cutting simulation to determine the friction model at the tool-chip interface suitable for metal cutting process. Cutting force experiments in orthogonal turning titanium alloy TI6AL4V are carried out with cement carbide tool KW10. The Coulomb frictions at the tool-chip interface are calculated based on measured cutting force, and the friction model is regressed, where cutting speed and feed rate are presented.

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.

Orthogonal Cutting of Biological Soft Tissue with Single Cutting Edge

2011 ◽  
Vol 121-126 ◽  
pp. 283-287
Author(s):  
Li Ying Gao ◽  
Qin He Zhang ◽  
Ming Liu
Keyword(s):  
Soft Tissue ◽  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Force Model ◽  
Porcine Liver ◽  
Tissue Cutting ◽  
Cutting Model ◽  
Biological Soft Tissue ◽  
Cutting Speeds

An orthogonal cutting model for investigating indentation type cutting of soft tissue was established, and the cutting force model was constructed theoretically based on fracture mechanics. A planar biological soft tissue cutting experimental setup was designed and developed to realize soft tissue cutting. Cutting experiments using orthogonal cutting blades were performed on fresh porcine liver at different cutting speeds. It was experimentally shown that the cutting speeds and the blade rake angles have significant effects on the penetration force and cutting force. Finally, a regression equation was obtained to explain the relationship among cutting force, cutting speed, and rake angle. These findings provide new insight into the biological soft tissue cutting.

Analytical Prediction of Three Dimensional Cutting Process—Part 1: Basic Cutting Model and Energy Approach

1978 ◽  
Vol 100 (2) ◽  
pp. 222-228 ◽  
Author(s):  
E. Usui ◽  
A. Hirota ◽  
M. Masuko
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Single Point ◽  
Orthogonal Cutting ◽  
Three Dimensional ◽  
Analytical Prediction ◽  
Forming Process ◽  
Proposed Model ◽  
Edge Based ◽  
Cutting Model

The paper proposes a new model of chip forming process in three dimensional cutting with single point tool, in which the process is interpreted as a piling up of orthogonal cuttings along the cutting edge. Based upon the proposed model, an energy method similar to the upper bound approach, which enables to predict the chip formation and the three components of cutting force by using only the orthogonal cutting data, is developed. The method is also applied to predict chip formation and cutting force in oblique cutting, plain milling, and groove cutting operations.

Investigation of Cutting Model in Machining of Al/SiCp Metal Matrix Composite

2011 ◽  
Vol 117-119 ◽  
pp. 1465-1470
Author(s):  
Sayed Mohamad Nikouei ◽  
Mohammad Ali Kouchakzadeh ◽  
R. Yousefi ◽  
M.A. Kadivar
Keyword(s):  
Chip Formation ◽  
Cutting Forces ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Shear Plane ◽  
Good Method ◽  
Depth Of Cut ◽  
Machining Forces ◽  
Experimental Cutting ◽  
Cutting Model

Prediction of shear plane angle is a way for prediction of the mechanism of chip formation, machining forces and so on. In this study, Merchant and Lee-Shaffer theories are used to predict the shear plane angles and cutting forces in machining of Al/SiCpMMC. The experimental cutting forces are compared with the calculated cutting force based on shear plane angles extracted from Merchant and Lee-Shaffer theories. The variation of these cutting forces with cutting speed, feed rate and depth of cut has been discussed. The results show that Merchant theory may be used as a good method for prediction of chip formation in machining of Al/SiCpMMC.

Study on Cutting Forces and Surface Finish During End Milling of Titanium Alloy

2014 ◽  
Author(s):  
Krishnaraj Vijayan ◽  
Samsudeen Sadham ◽  
Saikumar Sangeetha ◽  
Kuppan Palaniyandi ◽  
Redouane Zitoune
Keyword(s):  
Experimental Study ◽  
Titanium Alloy ◽  
Cutting Force ◽  
Cutting Tool ◽  
End Milling ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Dry Cutting ◽  
Cutting Speeds

This paper investigates numerical and experimental study of end milling of titanium alloy Ti–6% Al–4% V using carbide insert based cutting tool. The experiments were carried out under dry cutting conditions. The cutting speeds selected for the experiments are 20,30,40,50 mmin–1. The feed rates used in the experiment were 0.02, 0.04, 0.06 and 0.08 mmrev–1, while depth of cut is kept constant at 1.0 mm. For conducting the experiments single insert based cutting tool is based. For a range of cutting speeds and feeds measurements of cutting force, surface roughness and cutting temperature have been recorded. From the experimental study it can be seen that cutting speed has the significant effect on temperature when compared to feed/tooth. Further it is also found that cutting speed of 30 m min−1 and feed rate of 0.02 mm rev−1 could be used for machining Ti alloy. Moreover the experimental and numerical cutting force values are compared.

scholarly journals Surface Quality and Chip Formation in Turning of LM6 Aluminium Alloy and Particulate Reinforced Metal Matrix Composite

2013 ◽  
Vol 773-774 ◽  
pp. 894-901
Author(s):  
Muhammad Yusuf ◽  
M.K.A. Ariffin ◽  
N. Ismail ◽  
S. Sulaiman
Keyword(s):  
Surface Roughness ◽  
Aluminium Alloy ◽  
Surface Quality ◽  
Chip Formation ◽  
Feed Rate ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Cutting Condition

Majority of the components of aerospace and automotive vehicles need different machining operations, mainly for the assembly requirements. The components have to present both high dimensional precision and surface quality. This present work is concerned with the effect of cutting parameters (cutting speed, feed rate and depth of cut) on the surface roughness and the chip formation in turning process. The machining results are compared with LM6 aluminium alloy and TiC reinforced metal matrix composite under the same cutting conditions and tool geometry. The cutting condition models designed based on the Design of Experiments Response Surface Methodology. The objective of this research is to obtaining the optimum cutting parameters to get a better surface quality and also the chip formation and furthermore does not hazardous to the worker and the machined products quality. Results shows that Surface roughness values of LM6-TiC composite are higher as compared LM6 alloy at similar cutting condition. With increasing in cutting speed improves the surface quality. The surface quality increases with decrease of the feed rate and the depth of cut. There are difference chip forms for LM6 aluminium alloy and Al-TiC composite for a similar of cutting condition. Generally, chip formations of both materials are acceptable and favourable for the worker as well as the products and the tools.

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