Effect Mechanism of Nitrogen Gas on Chip Formation in High Speed Cutting of Ti6Al4V Alloy Based on FEM Simulation

Abstract:

Titanium alloys are known for their strong chemical reactivity with surrounding gas due to their high chemical affinity, especially in dry machining. This paper describes a study of chip formation characteristics under nitrogen gas media when machining Ti6Al4V alloy with WC-Co cemented carbide cutting tools at high cutting speeds. Based on the experimental study, a finite element model of two-dimensional orthogonal cutting process for Ti6Al4V alloy at different cutting conditions was developed using a commercial finite element software Deform-2D. Saw-tooth chips with adiabatic shear bands were produced in both experiments and simulations. And the enhanced cooling and anti-frictional effects of nitrogen gas upon the high speed cutting process of Ti6Al4V alloy were analyzed. Results of this investigation indicate that the anti-frictional performance of nitrogen gas has a significant effect on chip formation when machining Ti6Al4V alloy at high cutting speeds. Compared to air, Nitrogen gas is more suitable in improving the contact conditions at chip-tool interfaces and in increasing the shear band frequency of chip formation during high speed cutting of Ti6Al4V alloy.

• Periodical: Materials Science Forum (Volumes 626-627)
• Pages: 177-182
• DOI: https://doi.org/10.4028/www.scientific.net/MSF.626-627.177
• Online since: August 2009
• Authors: Wei Zhao, Ning He, Liang Li
• Keywords: Chip Formation, Finite Element (FE) Simulation, High-Speed Cutting, Nitrogen Gas, Ti-6Al-4V Alloy

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