3402 Finite Element Modelling of Chip Formation Process Applied to Drilling of Ti64 Alloy

Abstract

Titanium alloys are increasingly employed in the aerospace sector. Thus a better understanding of its behavior during machining process is needed in order to improve the productivity and reduce manufacturing costs. When machining titanium alloys, tool wear is associated to diffusion and attrition mechanisms, and thus stresses and temperature on the tool rake and clearance faces are relevant parameters to be measured. In most of the cases experimental approach is employed to better understand the behavior of cutting tools during titanium machining, but measurements of stresses and temperature not possible at this stage. Although having still many drawbacks, Finite Element Modelling of chip formation process has become a promising tool to understand machining process, and thus to help improving it. The commercial software Advantedge is employed to better understand the chip formation process when drilling Ti64 alloy. Analysis of cutting forces, temperatures and stresses carried out for several working conditions (cutting speed, feed rate, cutting tool edge radius...) in 2D. Force and temperature results are compared qualitatively against empirical ones carried out in previous reseasrch works in orthogonal conditions (2D) and 3D.

CAD-Based 3D-FE Modelling of AISI-D3 Turning with Ceramic Tooling

“…where τ f is the frictional shear stress, µ is the shear friction coefficient, and finally, σ n denotes the tool-chip interface stress. Studies related to the machining of steel [48,49] suggest using a value of friction coefficient between 0.5 and 0.6 in general. Since these values are also proposed by DEFORM™, the friction coefficient was set to 0.6 for the presented simulation runs.…”

Investigation of Dynamic Behavior and Process Stability at Turning of Thin-Walled Tubular Workpieces Made of 42CrMo4 Steel Alloy

“…Depending on the size of the mesh, the simulation results can sweep different morphologies of chips obtained experimentally. A decrease in the mesh size causes an uncontrollable increase in the values of the thrust-cutting force and the cutting energy [41]. The experimental results show that:…”

“…However, it can be stated that the average values of the radial, tangential, and axial cutting forces simulated using the FEM are lower than those measured experimentally. These can be explained using the results discussed by Bargue [40] and Arrazola et al [41]. Thus, according to Barge [40], the size of the mesh elements has an influence on the cutting forces and the radius of curvature of the chips, where extreme refinement can cause localization problems.…”

Implementation of CAD-based and 3D non-linear finite element methodologies on modelling of machining processes

“…The present research contributes towards both an experimental and a 3D numerical study on drilling of Al7075-T6, with solid carbide drills. The aim of this study is to develop a mathematical model, with the employment of Response Surface Methodology (RSM) and 3D Finite Element Method (FEM) [67][68][69][70][71][72][73][74][75][76], for predicting the generated thrust forces induced during Al7075-T6 drilling under commonly-used conditions. This way, most of the experimental work can be skipped and the preparation costs can be reduced.…”