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Title: Improved analytical prediction of chip formation in orthogonal cutting of titanium alloy Ti6Al4V
Authors: Bai, Wei
Sun, Ronglei
Roy, Anish
Silberschmidt, Vadim V.
Keywords: Orthogonal cutting
Chip formation
Analytical model
Chip segmentation
Titanium alloy
Issue Date: 2017
Publisher: © Elsevier
Citation: BAI, W. ... et al., 2017. Improved analytical prediction of chip formation in orthogonal cutting of titanium alloy Ti6Al4V. International Journal of Mechanical Sciences, 133, pp. 357-367.
Abstract: The aim of this paper is to propose an analytical model of chip formation for precise prediction of orthogonal cutting of Ti6Al4V. This alloy is used broadly in aerospace components; hence, prediction of thermomechanical parameters of its orthogonal cutting is crucial for various industrial applications. The suggested analytical model needs only cutting parameters and tool geometry as input; it can predict not only cutting forces but also main features of a primary shear zone and a tool-chip interface. A non-equidistant shear zone model is employed to calculate shear strains and a shear strain rate in the primary shear zone, and a simplified heat-transfer equation is used for temperature. A Calamaz-modified Johnson-Cook material model that accounting for flow softening at high strains and temperature-dependent flow softening is applied to assess shear stresses in the primary shear zone. In addition, a shear-angle solution is modified for Ti6Al4V. At the tool-chip interface, a contact length, equivalent strain and an average temperature rise are defined. Besides, the effect of sliding and apparent friction coefficients is investigated. For a sawtooth chip produced in the cutting process of Ti6Al4V, the segmented-chip formation is analysed. A chip-segmentation frequency and other parameters of the sawtooth chip are also obtained. The predicted results are compared with experimental data with the cutting forces, tool-chip contact length, shear angle and chip-segmentation frequency calculated with the developed analytical model showing a good agreement with the experiments. Thus, this analytical model can elucidate the mechanism of the orthogonal cutting process of Ti6Al4V including predictive capability of continuous and segmented chip formation.
Description: This paper is in closed access until 1st September 2018.
Sponsor: This work was supported by the National Basic Research Program of China (973 Program) grant No. 2013CB035805.
Version: Accepted for publication
DOI: 10.1016/j.ijmecsci.2017.08.054
URI: https://dspace.lboro.ac.uk/2134/26443
Publisher Link: https://doi.org/10.1016/j.ijmecsci.2017.08.054
ISSN: 0020-7403
Appears in Collections:Closed Access (Mechanical, Electrical and Manufacturing Engineering)

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