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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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