Silberschmidt_IJMS 2017 chip for LUPIN.pdf (3.37 MB)
Improved analytical prediction of chip formation in orthogonal cutting of titanium alloy Ti6Al4V
journal contribution
posted on 2017-09-11, 13:13 authored by Wei Bai, Ronglei Sun, Anish RoyAnish Roy, Vadim SilberschmidtVadim SilberschmidtThe 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.
Funding
This work was supported by the National Basic Research Program of China (973 Program) grant No. 2013CB035805.
History
School
- Mechanical, Electrical and Manufacturing Engineering
Published in
International Journal of Mechanical SciencesVolume
133Pages
357 - 367Citation
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.Publisher
© ElsevierVersion
- AM (Accepted Manuscript)
Publisher statement
This work is made available according to the conditions of the Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International (CC BY-NC-ND 4.0) licence. Full details of this licence are available at: https://creativecommons.org/licenses/by-nc-nd/4.0/Publication date
2017Notes
This paper was published in the journal International Journal of Mechanical Sciences and the definitive published version is available at https://doi.org/10.1016/j.ijmecsci.2017.08.054.ISSN
0020-7403Publisher version
Language
- en