A Lagrangian FEM Model to Produce Saw-Toothed Macro-Chip and to Study the Depth of Cut Influence on its Formation in Orthogonal Cutting of Ti6Al4V

Abstract:

The foundations of micro-milling are similar to macro-milling but the phenomena it involves are not a simple scaling-down of macro-cutting. The importance of the minimum chip thickness is one of the significant differences between the two processes. The lagrangian FEM model presented in this paper aims to study the depth of cut influence on chip formation of Ti6Al4V in orthogonal cutting. It is firstly used to compare the modelled saw-toothed macro-chip morphology and cutting forces to experimental cutting results from literature. Then a minimum chip thickness prediction is performed by decreasing the depth of cut. Finally this study is the opportunity to highlight the specific features of micro-cutting reported in literature, such as the effective negative rake angle of the tool or the size effect. The model presented brings therefore a numerical contribution to the comprehension of these phenomena.

• Periodical: Advanced Materials Research (Volume 223)
• Pages: 3-11
• DOI: https://doi.org/10.4028/www.scientific.net/AMR.223.3
• Online since: April 2011
• Authors: François Ducobu, Edouard Rivière-Lorphèvre, Enrico Filippi
• Keywords: Chip Formation, Elastic Spring Back, Lagrangian, Minimum Chip Thickness, Saw-Toothed Chip, Size Effect, Ti6-Al-4V

References

[1] Chae, J., Park, S., Freiheit, T.: Int. J. Machine Tools and Manufacture, 45 (2006), pp.313-332.

[2] Weule, H., Hüntrup, V., Trischler, H.: Annals of the CIRP, 50 (2001), pp.61-64.

[3] Simoneau, A., Ng, E., Elbestawi, M.A.: Int. J. Machine Tools and Manufacture, 46 (2006), pp.467-481.

[4] Filiz, S., Conley, C., Wasserman, M., Ozdoganlar, O.: Int. J. Machine Tools and Manufacture, 47 (2007), pp.1088-1100.

DOI: 10.1016/j.ijmachtools.2006.09.024

[5] Calamaz, M., Coupard, D., Girot, F.: Int. J. Machine Tools and Manufacture, 48 (2008), pp.275-288.

[6] Ducobu, F., Filippi, E., Rivière-Lorphèvre, E.: Proceedings of the 12th CIRP Conference on Modeling of Machining Operations, (2009), pp.339-346.

[7] Ducobu, F., Rivière-Lorphèvre, E., Filippi, E.: Proceedings of the Eighth International Conference on High Speed Machining, (2010), pp.202-207.

[8] Ducobu, F., Filippi, E., Rivière-Lorphèvre, E.: Proceedings of the 9th International Conference on Laser Metrology, CMM and Machine Tool Performance, (2009), pp.327-336.

[9] Nasr, M., Ng, E.G., Elbestawi, M., Proc. IMechE, Part B: J. Engineering Manufacture, 221 (2007), pp.1387-1400.

[10] Sun, S., Brandt, M., Dargusch, M.S.: Int. J. Machine Tools and Manufacture, 49 (2009), pp.561-568.

[11] Özel, T., Zeren, E.: Int. J. Machining and Machinability of Materials, 2 (2007), pp.451-468.

[12] Lesuer, D.R., 2000, Experimental investigations of Material Models for Ti-6Al-4V Titanium and 2024-T3 Aluminum, Lawrence Livermore National Laboratory.

[13] Bäker, M., Rösler, J., Siemers, C.: Comput. Struct., 80 (2002), pp.495-513.

[14] Woon, K.S., Rahman, M., Fang, F.Z., Neo, K.S., Liu, K.: J. Materials Processing Technology, 167 (2007), pp.316-337.

[15] Vogler, M.P., DeVor, R.E., Kapoor, S.G.. J. Manufacturing Science and Engineering, 126 (2004), pp.695-705.

[16] Jun, M.B.G., DeVor, R.E., Kapoor, S.G.: ASME, 128 (2006), pp.901-912.

[17] Vogler, M.P., DeVor, R.E., Kapoor, S.G.: J. Manufacturing Science and Engineering, 126 (2004), pp.685-694.