Numerical Simulation of Cutting Force and Temperature Field in High Speed Machining of Titanium Alloys

Abstract:

Improvements in manufacturing technologies require better modeling and simulation of metal cutting processes. A fully thermal-mechanical coupled finite element analysis (FEA) was applied to model and simulate the high speed machining of TiAl6V4. The development of serrated chip formation during high speed machining was simulated. The effects of rake angle on chip morphology, cutting force and the evolution of the maximum temperature at the tool rake were analyzed with the finite element model. The simulation results show that the segmented chip formation results in cutting force fluctuation. Although the segmentation frequency of the chip increases with the increase of the rake angle, the degree of segmentation becomes weaker and the cutting force fluctuation amplitude decreases. The predicted temperature distribution during the cutting process is consistent with the experimental results given in a literature.

• Periodical: Applied Mechanics and Materials (Volumes 37-38)
• Pages: 731-734
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.37-38.731
• Online since: November 2010
• Authors: Cong Ming Yan, You Xi Lin
• Keywords: Cutting Force, Finite Element Model (FEM), High Speed Machining (HSM), Temperature Field, Titanium Alloy

References

[1] C.H. Che-Haron and A. Jawaid: Journal of Materials Processing Technology, Vol. 166 (2005) No. 2, p.188–192.

[2] D.R. Sandstrom and J.N. Hodowany: Machining Science and Technology, Vol. 2(1998) No. 2, p.343–353.

[3] D. Umbrello: Journal of Materials Processing Technology, Vol. 196 (2008) No. 1-3, pp.79-87.

[4] C. Madalina, C. Dominique and G. Franck: International Journal of Machine Tools and Manufacture, Vol. 48 (2008) No. 3-4, pp.275-288.

[5] J. Zhao, H. Meng and S.Y. Wang: Tool Engineering, Vol. 39 (2005) No. 1, pp.29-31.

[6] J. Hua and R. Shivpuri: Journal of Materials Processing Technology, Vol. 150 (2004) No. 1-2, p.124–133.

[7] C. Hortig and B. Svendsen: Journal of Materials Processing Technology, Vol. 186 (2007) No. 1-3, pp.66-76.

[8] S.H. Lu and N. He: Ordnance Material Science and Engineering, Vol. 32 (2009) No. 1, pp.5-9.

[9] T. Mabrouki and J.F. Rigal: Journal of Materials Processing Technology, vol. 176 (2006) No. 1-3, pp.214-221.

[10] D.R. Lesuer: NTIS, DOT/FAA/AR-00/25, 2000. 9.

[11] W. Grzesik, M. Bartoszuk and P. Nieslony: Journal of Materials Processing Technology, Vol. 164-165 (2005), pp.1204-1211.

DOI: 10.1016/j.jmatprotec.2005.02.136

[12] R. Mustafizur, Z.G. Wang and Y. S Wong: JSME International Journal, Series C: Mechanical Systems, Machine Elements and Manufacturing, Vol. 49 (2006)No. 1, pp.11-20.

[13] D.R. Sandstrom and,J.N. Hodowany: Machining Science and Technology, Vol. 2 (1998) No. 2, p.343–353.

[14] S. Guy, R. Nicolas, M. Alain and P. Vincent: International Journal of Machining and Machinability of Materials, Vol. 3(2008) No. 1-2, pp.52-61.