Finite Element Simulation of PCD Tool Cutting Titanium Alloy

2013 ◽  
Vol 589-590 ◽  
pp. 64-69
Author(s):  
Xian Li Liu ◽  
Jia Yi Zhang ◽  
Yu Wang ◽  
Cai Xu Yue ◽  
Fei Liu
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Pcd Tool ◽  
Element Simulation ◽  
Force Increase ◽  
Tool Cutting ◽  
Deform 3D

Titanium alloy is widely applied in various fields, but it’s a sort of difficult-to-cut material. In this paper, DEFORM-3D is used to carry on a simulation of PCD tool milling Ti6A14V. Variation curves of cutting temperature and cutting force are obtained by changing cutting speed, feed per tooth and axial cutting depth. Further, the effect of cutting parameters on cutting temperature and cutting force is revealed. The research shows that cutting temperature and cutting force increase with cutting parameters. In addition, single factor experiments are conducted to verify that the results of the experiments are in consistent with those of the simulation, and that the simulation model is correct. The results will provide new methods for studies of cutting temperature and cutting force of PCD tool milling Ti6A14V.

An Experimental Study of Cutting Force on Large Cutting Depth Turning Titanium Alloy with CBN Tool

2014 ◽  
Vol 800-801 ◽  
pp. 237-240
Author(s):  
Li Fu Xu ◽  
Ze Liang Wang ◽  
Shu Tao Huang ◽  
Bao Lin Dai
Keyword(s):  
Experimental Study ◽  
Titanium Alloy ◽  
Cutting Force ◽  
Feed Rate ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Depth ◽  
Cbn Tool ◽  
Cutting Experiment ◽  
Rough Turning

In this paper, the cutting experiment was used to study the influence of various cutting parameters on cutting force when rough turning titanium alloy (TC4) with the whole CBN tool. The results indicate that among the cutting speed, feed rate and cutting depth, the influence of the cutting depth is the most significant on cutting force; the next is the feed rate and the cutting speed is at least.

Experimental Investigation of Mechanical-Thermal Characteristics in High Efficiency Turning Titanium Alloy Ti6Al4V

2016 ◽  
Vol 836-837 ◽  
pp. 20-28
Author(s):  
Li Min Shi ◽  
Cheng Yang ◽  
Qi Jun Li
Keyword(s):  
Titanium Alloy ◽  
Tool Wear ◽  
Cutting Force ◽  
High Efficiency ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Thermal Characteristics ◽  
Tool Failure ◽  
Minimal Quantity Lubrication ◽  
Titanium Alloy Ti6al4v

Titanium alloy Ti6Al4V has poor machinability, which leads to high unit cutting force and cutting temperature, rapid tool failure. In this study, the effect of the cutting speed, feed rate and cooling condition on cutting force and cutting temperature is critically analysed by turning experiment. At the same time, the relationship is established among tool wear, cutting force and cutting temperature. This investigation has shown that cutting speed is the decisive factor which increasing cutting force and cutting temperature. In the process of turning, tool wear results in high amounts of heat and mechanical stress, which leads to serious tool wear. The Minimal Quantity Lubrication reduces the frictional condition at the chip-tool, decreases cutting force and cutting temperature, and delays the tool failure.

Cutting Performance and Failure Mechanisms of Coated Carbide Tools in Face Milling Powder Metallurgy Nickel-Based Superalloy

2012 ◽  
Vol 497 ◽  
pp. 94-98
Author(s):  
Yang Qiao ◽  
Xiu Li Fu ◽  
Xue Feng Yang
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Failure Mechanisms ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Face Milling ◽  
Nickel Based Superalloy ◽  
Coated Carbide ◽  
Coated Carbide Tools

Powder metallurgy (PM) nickel-based superalloy is regarded as one of the most important aerospace industry materials, which has been widely used in advanced turbo-engines. This work presents an orthogonal design experiments to study the cutting force and cutting temperature variations in the face milling of PM nickel-based superalloy with PVD coated carbide tools. Experimental results show that with the increase of feed rate and depth of cut, there is a growing tendency in cutting force, with the increase of cutting speed, cutting force decreases. Among the cutting parameters, feed rate has the greatest influence on cutting force, especially when cutting speed exceeds 60m/min. With the increase of all the cutting parameters, cutting temperature increases. However the cutting temperature increases slightly as the increasing of feed rate. Tool failure mechanisms in face milling of PM nickel-based superalloy are analyzed. It is shown that the breakage and spalling on the cutting edge are the most dominate failure mechanisms, which dominates the deterioration and final failure of the coated carbide tools.

Finite Element Simulation on High Speed Cutting of Hardened 45 Steel Based on ABAQUS

2013 ◽  
Vol 579-580 ◽  
pp. 202-207
Author(s):  
Guo He Li ◽  
Hou Jun Qi ◽  
Bing Yan
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Finite Element Simulation ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Cutting Process ◽  
High Speed Cutting ◽  
Geometry Model ◽  
Element Simulation

For the high speed cutting process of hardened 45 steel (45HRC), a finite element simulation of cutting deformation, cutting force and cutting temperature is finished with the large general finite element software ABAQUS. Through the building of geometry model, material model and heat conduction model, also the determination of boundary conditions, separation rule and friction condition, a thermal mechanical coupling finite element model of high speed cutting for hardened 45 steel is built. The serrated chip, cutting force and cutting temperature can be predicted. The comparison of experiment and simulation shows the validity of the model. The influence of cutting parameters on cutting process is investigated by the simulation under different cutting depthes and rake angles. The results show that as the increase of rake angle, the segment degree, cutting force and cutting temperature decrease. But the segment degree, also the cutting force and cutting temperature increase with the increase of cutting depth. This study is useful for the selection of cutting parameters of hardened steel.

A Parametric Optimization on Cutting Force during Laser Assisted Machining of Inconel 718 Alloy

2015 ◽  
Vol 787 ◽  
pp. 460-464 ◽  
Author(s):  
M. Vignesh ◽  
K. Venkatesan ◽  
R. Ramanujam ◽  
P. Kuppan
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Inconel 718 ◽  
Laser Power ◽  
Laser Cutting ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Work Piece ◽  
Conventional Machining

Inconel 718, a nickel based alloys, addressed as difficult to cut material because of hard carbide particle, hardness, work hardening and low thermal conductivity. Improving the machinability characteristics of nickel based alloys is a major anxiety in aircraft, space vehicle and other manufacturing fields. This paper presents an experimental investigation in Laser assisted turning of Inconel 718 to determine the effects of laser cutting parameters on cutting temperature and cutting forces. This nickel alloy has a material hardness at 48 HRC and machined with TICN/Al2O3/TiN tool. This is employed for the manufacture of helicopter rotor blades and cryogenic storage tanks. The experiments were conducted at One-Factor-at-a-Time.The effects of laser cutting parameters, namely cutting speed, feed rate, laser power and laser to work piece angle, on the cutting temperature and cutting force components, are critically analysed and the results are compared with unassisted machining of this alloy. The experiments are conducted by varying the cutting speed at three levels (50, 75, 100 m/min), feed rate (0.05, 0.075 0.1 mm/rev), laser power (1.25 kW, 1.5 kW, 1.75 kW) and at two level laser to work piece angle (60, 75°). At the optimal parametric combinationof laser power 1.5 kW with cutting speed of 75m/min, feed rate of 0.075 mm/min and laser to work piece angle 60°, the benefit of LAM was shown by 18%, 25% and 24% decrease in feed force (Fx), thrust force (Fy) and cutting force (Fz) as compared to those of the conventional machining. Examination of the machined surface hardness profiles showed no change under LAM and conventional machining.

Parameters Optimization about Precision Milling Titanium Alloy TC4 Used for Aviation

2012 ◽  
Vol 472-475 ◽  
pp. 1818-1822
Author(s):  
Wei Hua Wu ◽  
Yan Yan Guo ◽  
Can Zhao ◽  
Tao Xu ◽  
Jia Yang
Keyword(s):  
Surface Roughness ◽  
Titanium Alloy ◽  
Cutting Force ◽  
Production Efficiency ◽  
Design Method ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Parameters Optimization ◽  
Processing Efficiency

To improve the production efficiency and product quality of titanium alloy TC4, with the minimum of cutting force F, surface roughness Ra, and surface peak valley height Pv as the optimized goal, using orthogonal rotating combination design method of three factors quadratic regression, the influence of cutting speed vc, feed per tooth fz and cutting width ae to cutting force (Fx, Fy) surface peak valley height Pv and surface roughness Ra are mainly studied, and the best cutting amount combination is chosen. Experiment results indicate that the best cutting parameters of titanium alloy are vc=28.588 m/min、fz=0.043 3 mm/z、ae=0.1 mm, the optimal values are =3.346 N、 =47.01 N、 =673.89 nm and =201.78 nm. This research is of theoretical significance for improving the processing efficiency and machining quality and reducing the production cost.

Prediction of Temperature in Turning Ti6Al4V

2014 ◽  
Vol 555 ◽  
pp. 518-523
Author(s):  
Diana Andreea Coroni ◽  
Sorin Mihai Croitoru
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Titanium Alloy ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Ti6al4v Titanium Alloy ◽  
Maximum Value ◽  
Simulated Case ◽  
Deform 3D

Due to their special and important properties, titanium and its alloys are attractive materials to be used in the industry. This paper presents 3D simulation cases used in optimization of Ti6Al4V titanium alloy turning. The output parameter is the temperature while the input parameters were the machining ones: cutting speed, feed and depth of cut. For simulations, the software based on finite element method - DEFORM 3D© - was used. Finally, the cutting temperature can be considered 2/3 of the maximum value of the temperature range of each simulated case. This statement was verified by real experiments.

Force and Temperature in Dry Cutting of Hardened W18Cr4V with PCBN

2010 ◽  
Vol 431-432 ◽  
pp. 559-563
Author(s):  
Hai Rong Wu ◽  
Guo Qin Huang ◽  
Xi Peng Xu
Keyword(s):  
Experimental Study ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Depth ◽  
Dry Cutting ◽  
Feeding Speed ◽  
Strain Gauge Dynamometer ◽  
Three Components

An experimental study was carried out to investigate the effects of cutting parameters on cutting force and temperature in cutting of hardened W18Cr4V with PCBN cutter. Three components of cutting force were recorded by a strain-gauge dynamometer and the cutting temperature was measured by a nature thermocouple of tool-workpiece. The cutting parameters were arranged by orthogonal method. It is shown that the cutting temperature increased with each of the three cutting parameters and the main effecting factor is feeding speed. The three components of cutting force increased greatly with an increase in feeding speed and cutting depth. But the forces decreased a little as cutting speed increased. The main and axial cutting forces depend mainly on cutting depth whereas the radius force is mainly influenced by feeding speed.

scholarly journals Experimental Evaluation in Dry Machining of Inconel 718 Using Coated Carbides

2020 ◽  
pp. 1-11
Author(s):  
M. M. Reddy ◽  
N. S. Reddy ◽  
J. N. Evan
Keyword(s):  
Cutting Force ◽  
Feed Rate ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
High Hardness ◽  
Cutting Parameters ◽  
Depth Of Cut ◽  
Work Piece ◽  
Ceramic Tools ◽  
Optimal Cutting Parameters

Past two decades, the usage of ceramic tools has increased especially in milling and turning process. These advanced ceramic tools have good characteristics that are capable in maintaining high hardness in temperatures and also wears much slower when compared to carbide tools. With limited data available on the tool itself, research is to be done on these advance ceramic tools. The main purpose of this research project is to determine the cutting parameters affecting the cutting temperature and cutting force. The cutting parameters are cutting speed, depth of cut and feed rate. Silicon Nitride is chosen as the tool and Steel AISI4140 is chosen as the work piece. Analysis is conducted through Box-Behnken method with 3 levels, 3 factors and 2 responses. The regression model for cutting temperature and cutting force responses are identified. Analysis of Variance (ANOVA) is done to determine the effect of the cutting parameters and their contribution towards the cutting temperature and cutting force response. It is found that feed rate has the most influence on cutting temperature and force. The optimal cutting parameters that produce the lowest cutting temperature and lowest cutting force are also obtained.

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.

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