scholarly journals Phenomenological study of chip flow/formation and unified cutting force modelling during Ti6Al4V alloy turning operations

Procedia CIRP ◽  
2018 ◽  
Vol 77 ◽  
pp. 351-354 ◽  
Author(s):  
Iheb Chérif ◽  
Théo Dorlin ◽  
Bertrand Marcon ◽  
Guillaume Fromentin ◽  
Habib Karaouni
Keyword(s):  
Cutting Force ◽  
Phenomenological Study ◽  
Ti6al4v Alloy ◽  
Turning Operations ◽  
Chip Flow ◽  
Flow Formation

scholarly journals Numerical Modeling and Analysis of Ti6Al4V Alloy Chip for Biomedical Applications

Materials ◽  
2020 ◽  
Vol 13 (22) ◽  
pp. 5236
Author(s):  
Waqas Saleem ◽  
Bashir Salah ◽  
Xavier Velay ◽  
Rafiq Ahmad ◽  
Razaullah Khan ◽  
...  
Keyword(s):  
Damage Model ◽  
Equivalent Plastic Strain ◽  
Chip Morphology ◽  
Cutting Parameters ◽  
Ti6al4v Alloy ◽  
Contact Friction ◽  
Fracture Mechanisms ◽  
Modeling And Analysis ◽  
Micro Scale ◽  
Chip Flow

The influence of cutting forces during the machining of titanium alloys has attained prime attention in selecting the optimal cutting conditions to improve the surface integrity of medical implants and biomedical devices. So far, it has not been easy to explain the chip morphology of Ti6Al4V and the thermo-mechanical interactions involved during the cutting process. This paper investigates the chip configuration of the Ti6Al4V alloy under dry milling conditions at a macro and micro scale by employing the Johnson-Cook material damage model. 2D modeling, numerical milling simulations, and post-processing were conducted using the Abaqus/Explicit commercial software. The uncut chip geometry was modeled with variable thicknesses to accomplish the macro to micro-scale cutting by adapting a trochoidal path. Numerical results, predicted for the cutting reaction forces and shearing zone temperatures, were found in close approximation to experimental ones with minor deviations. Further analyses evaluated the influence of cutting speeds and contact friction coefficients over the chip flow stress, equivalent plastic strain, and chip morphology. The methodology developed can be implemented in resolving the industrial problems in the biomedical sector for predicting the chip morphology of the Ti6Al4V alloy, fracture mechanisms of hard-to-cut materials, and the effects of different cutting parameters on workpiece integrity.

Experimental Research on Effect of Thermohydrogen Treatment on Machinability of Ti6Al4V Alloy

2010 ◽  
Vol 129-131 ◽  
pp. 426-429
Author(s):  
Yu Chao ◽  
Jian Ye Guo ◽  
Jing Kui Li ◽  
Yan Li Zhang
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Experimental Research ◽  
Hydrogen Content ◽  
Turning Point ◽  
Chip Morphology ◽  
Ti6al4v Alloy ◽  
Peak Value

By turning testing workpieces of different hydrogen content Ti6Al4V alloy, measuring cutting force and surface roughness as well as observing chip morphology, the effect of hydrogen content on machinability of Ti6Al4V alloy has been studied. Results of this experiment indicate that machinability of Ti6Al4V alloy improves with increasing hydrogen content at a certain range of hydrogen content, and there is a turning point of peak value, in excess of the hydrogen value, with the hydrogen content increasing, machinability of Ti6Al4V alloy is reduced.

Predictive Cutting Force Model and Cutting Force Chart for Milling with Cutter Axis Inclination

2013 ◽  
Vol 7 (1) ◽  
pp. 30-38 ◽  
Author(s):  
Takashi Matsumura ◽  
◽  
Motohiro Shimada ◽  
Kazunari Teramoto ◽  
Eiji Usui ◽  
...  
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Flow Direction ◽  
Three Dimensional ◽  
Shear Plane ◽  
Cutting Parameters ◽  
Force Model ◽  
Chip Flow ◽  
Inclination Angles ◽  
Cutting Model

A force model for milling with cutter axis inclination is presented. The model predicts the cutting force and chip flow direction. Three-dimensional chip flow is interpreted as a piling up of the orthogonal cuttings in the planes containing the cutting velocities and the chip flow velocities in the inclined coordinate system with a ball end mill. The chip flow direction is determined to minimize the cutting energy consumed into the shear energy on the shear plane and the friction energy on the rake face. Then, the cutting force is predicted in the chip flow determined model. The presented cutting model is verified by comparing the predicted cutting forces to the measured forces in the actual cutting tests. As an advantage of the presented force model, the change in the chip flow direction during one rotation of the cutter is also predicted in the simulation for the cutter axis inclination and the cutting parameters. In the simulation, the effect of cutter axis inclination on the cutting process is discussed in terms of the tool wear and surface finish. The cutting force charts, in which the maximum values of the positive and the negative cutting forces are simulated for the inclination angles, are presented to review the cutter axis inclination. The applicable cutter axis inclination can be determined by taking into account the thresholds of the cutting force components.

SPH/FE modeling of cutting force and chip formation during thermally assisted machining of Ti6Al4V alloy

2014 ◽  
Vol 84 ◽  
pp. 188-197 ◽  
Author(s):  
Yao Xi ◽  
Michael Bermingham ◽  
Gui Wang ◽  
Matthew Dargusch
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Ti6al4v Alloy ◽  
Fe Modeling

Determination of Cutting Forces in Oblique Cutting

2015 ◽  
Vol 756 ◽  
pp. 659-664 ◽  
Author(s):  
A.V. Filippov ◽  
E.O. Filippova
Keyword(s):  
Cutting Force ◽  
Cutting Forces ◽  
Theoretical Calculations ◽  
Experimental Investigations ◽  
Cutting Depth ◽  
Turning Operations ◽  
Error Check ◽  
Cutting Force Components ◽  
Force Components

This study describes the method of determining cutting force components in oblique turning. The scheme of how the investigations were performed is presented. The characteristic curves of cutting force components vs. thickness of the material removed, tool clearance and tool rake angles are shown. The study presents the data, which have been obtained during the experimental investigations and analytically calculated, on how the cutting forces are subject to changes depending on a cutter angle, cutting depth and feed in oblique turning operations. The analysis of approximation of the experimental results and error check of the theoretical calculations relative to the experimental data are given.

Finite Element Simulation of Ultrasonic Vibration Orthogonal Cutting of Ti6Al4V

2010 ◽  
Vol 97-101 ◽  
pp. 1933-1936 ◽  
Author(s):  
Zhi An Tang ◽  
Chang Yi Liu ◽  
Jun Jie Yi
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Contact Region ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Chip Flow ◽  
Strain And Strain Rate ◽  
Model Combining ◽  
Clearance Face

In this paper Finite Element Methods (FEM) were used to simulate the ultrasonic vibration Orthogonal cutting of titanium alloy Ti6Al4V. Machining conditions were similar to those used for manufacture. Material constitutive applied Johnson-Cook model combining elastic and plastic deformation, the material hardening for extreme shear strain and strain rate, material softening for adiabatic shear of chip flow-zone. Chip separated criteria adopted arbitrary Lagrangian Euler algorithm (ALE). Heat sources included the rake face chip flow under conditions of seizure and chip/tool friction, clearance face tool/workpiece friction. Thus, the orthogonal ultrasonic vibration machining of Ti6Al4V FEM models were established. The simulation results included the chip formation, the cutting force/stress and temperature distributions through the primary shear zone and the chip/tool contact region. The cutting force, cutting temperature of the ultrasonically and conventionally machining were compared. The reasons of the decrease of chip deformation coefficients, cutting force and temperature and the increase of shear angle in ultrasonic machining were discussed.

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