Papers by Author: D. Coupard

Abstract: Improving the cutting processes by optimizing operating parameters necessarily involves understanding the thermo-mechanical mechanisms generated during chip formation. For this, numerical simulations are used to obtain the strain, stress and thermal fields near the tool tip. Nowadays, the validation of numerical simulation models of cutting is based on macroscopic results such as chip geometry and cutting forces generated by the machining process. However, it is not appropriate to validate local fields by macroscopic results. So, it is important to validate numerical cutting simulations on the bases of measured local strain fields. This article aims to study the feasibility of strain field measurement in orthogonal machining of the titanium alloy Ti64. A high-speed camera was used to provide data for segmented chip formation analysis. A microscope was related to the camera to observe an area of about 0.7x0.7mm² around the tool tip. An optimum adjustment of camera settings, lighting, workpiece surface preparation and cutting conditions allowed to obtain an acceptable image quality for analyzing with Correli [1] software. At low cutting speed, Correli qualitatively identify the position of the primary shear band and its evolution over the time.

Abstract: During chip formation, material is subjected to high deformations and high strain rates which generate high pressures and temperatures. Cutting fluids have an important role but produce many constraints: cleaning of parts, environment quality degradation, cost increase, diseases as identified by the European Agency for Safety and Health at Work. Dry machining is one of the future challenges although its implementation remains delicate, in particular for TiAl6V alloy. This paper aims at correlating the contact conditions at the tool/chip interface with the tool wear to understand the wear mechanisms of carbide tools in dry machining. Numerical simulations, experimentally validated, allow pointing out that the temperature distribution at the tool/chip interface depends on chip type (continuous, serrated). For continuous chips, the temperature is fairly uniform and stationary throughout the interface. For segmented chips, a cold zone between two temperature peaks is observed and moves along the tool rake face during the formation of a chip segment. The evolution of the normal stress at the interface is similar for both types of chips at the beginning of the localization phenomenon. These pressure and temperature fields allow the titanium to diffuse into the tungsten carbide and form the mixed carbide (Ti, W)C, which is very sensitive to oxidation above 500°C. This could explain the attrition of the tool, due to the brittleness of the oxycarbides. Contact conditions and tool wear are finally correlated.