3D Finite Element Modeling of the Machining of Ti6Al4V Alloys

Yang, Ji Hong; Sun, Shoujin; Brandt, Milan; Yan, Wenyi

doi:10.4028/www.scientific.net/amr.189-193.1926

Cited by 4 publications

(2 citation statements)

References 13 publications

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“…The generation of the meshes is the most important part and the uniformity of the mesh determines whether the force distribution will also be uniform. 19,20 By refining the meshes, especially those in the area relating to the distribution of milling force, they can mostly be divided into tetrahedra. Most of them are second-order elements, for which the mesh quality does not need to be very great.…”

Section: Simulation Analysis Of the Stress Fieldmentioning

confidence: 99%

Investigation on the stress field of milling titanium alloys with micro-textured ball-end milling cutter

Yang

Zheng

2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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In the milling of titanium alloy, the distribution of milling force and its related law of change seriously affect the physical properties of workpiece materials, the stress distribution on a cutter’s rake face and the interaction between the workpiece, the cutter and the chip. This article reports on a study of the stress field distribution under the conditions of anti-friction and anti-wear when cutting titanium alloy with a micro-textured ball-end milling cutter. Milling test data were used to establish empirical models of milling force and the contact area between the cutter and the chip. Based on this, the force density function of the cutter coordinate system was obtained and the equivalent stress and displacement of the cutter were simulated and analyzed. This in turn provided the means to acquire the instantaneous stress and strain relating to the cutter at any time. Analysis of the simulation results shows that the position in which the stress and strain are concentrated on the cutter is consistent with actual processing. This confirms the accuracy of the force density function and provides the basis for further study of thermo-mechanical coupling behaviors when engaged in using micro-textured ball-end milling cutters for the cutting of titanium.

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Section: Simulation Analysis Of the Stress Fieldmentioning

confidence: 99%

Investigation on the stress field of milling titanium alloys with micro-textured ball-end milling cutter

Yang

Zheng

2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…The finite element method can provide the detailed instantaneous information such as the formation/evolution of shear bands and the initiation/propagation of the cracks, which provides a solution for the study of the formation mechanism of discontinuously segmented chip. Yang et al (2011) developed a 3D finite element model for high-speed machining, the formation of the discontinuously segmented chip was captured. Wang et al (2018) studied the influences of material constitutive and fracture parameters on the chip formation in high-speed cutting of Inconel 718.…”

Section: Introductionmentioning

confidence: 99%

The formation mechanism of discontinuously segmented chip in high-speed cutting of Ti-6Al-4V

Ye,

Li,

Zhang

et al. 2023

Preprint

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The chip transition from continuously serrated to discontinuously segmented is one of the most fundamental and challenging problems in metal cutting. In this work, a reliable finite element model for high speed cutting of Ti-6Al-4V was developed based on the high speed cutting experiments. The Johnson-Cook (J-C) constitutive parameters of the Ti-6Al-4V were optimized using the response surface method (RSM) and multi-objective genetic algorithm to accurately describe the plastic behavior of Ti-6Al-4V alloy in high speed cutting. With using the optimized constitutive parameters, the simulated chip morphologies and cutting forces match well with the experimental results in a wide range of cutting speed from 0.05 m/s to 86.5 m/s. The formation mechanism of the discontinuously segmented chip was further studied based on the validated finite element model. The results reveal that three distinct cracks form successively in the segmented chip formation process: the crack I forms at chip root, the cracks II and III initiate at the primary shear zone center and chip free surface respectively and propagate along the direction of maximum stress triaxiality to seperate the chip and workpiece. The crack I, which forms at the chip root due to the maturely evolved shear banding, is the key reason for the transition of chip formation from continuously serrated to discontinuously segmented.

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The formation mechanism of discontinuously segmented chip in high-speed cutting of Ti-6Al-4 V

Ye,

Li,

Zhang

et al. 2023

Int J Adv Manuf Technol

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3D Finite Element Modeling of the Machining of Ti6Al4V Alloys

Cited by 4 publications

References 13 publications

Investigation on the stress field of milling titanium alloys with micro-textured ball-end milling cutter

Investigation on the stress field of milling titanium alloys with micro-textured ball-end milling cutter

The formation mechanism of discontinuously segmented chip in high-speed cutting of Ti-6Al-4V

The formation mechanism of discontinuously segmented chip in high-speed cutting of Ti-6Al-4 V

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