3D Simulation of Laser Assisted Side Milling of Ti6Al4V Alloy Using Modified Johnson-Cook Material Model

Zamani, Hassan Adrian; Hermani, Jan-Patrick; Sonderegger, Bernhard; Sommitsch, Christof

doi:10.4028/www.scientific.net/kem.554-557.2054

Cited by 8 publications

(4 citation statements)

References 6 publications

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“…The main objective is to achieve thermal softening in the entire cutting region. It is understood from literature survey that the temperature of 250-300 • C in the cutting zone is desired for an optimal machining characteristics of Ti6Al4V [13]. Consequently, the range of laser parameters is selected to achieve temperature around 300 • C in the cutting zone.…”

Section: Resultsmentioning

confidence: 99%

“…Ayed et al [12] performed a 2D simulation of laser-assisted orthogonal cutting of Ti-alloy based on FEM and found that a 4-55 % reduction in cutting forces by varying laser power and laser-tool gap. Further, Zamani et al [13] performed 3D simulation of laser-assisted side milling of Ti6Al4V and observed 25-60 % reduction in the cutting forces. Many researchers analyzed laser heating for difficult to machine alloys to achieve optimum heat-affected depth and width to improve their machinability.…”

Section: Introductionmentioning

confidence: 99%

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A 3D FEM-based model of laser heating and machining for selection of process parameters and scanning path in laser-assisted machining of Ti6Al4V

Divse

Dubey

Marla

2022

Preprint

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An appropriate selection of the laser parameters is critical in realizing the potential of laser-assisted machining (LAM) for hard-to-cut materials. This work presents a 3D FEM-based model of laser heating in laser-assisted machining of Ti6Al4V to select the laser parameters. The model accounts for the effect of the laser-tool gap, laser scanning speed, laser power, and laser path (linear and sinusoidal). The laser heating is modeled using a moving continuous heat source with a Gaussian intensity distribution, implemented in Abaqus/explicitTM with the help of a VDFLUX subroutine. The results suggest that the laser-tool gap plays a significant role in heating the entire cutting region. Regardless of power and scanning speed, the laser-tool gap must be sufficient to allow heating of the cutting region. The laser power should be sufficient to soften the material in the cutting zone, but it can be minimized by choosing an optimal value of the laser-tool gap. Also, sinusoidal laser scanning produced the desired thermal softening effects at lower laser powers than linear laser scanning. Accordingly, similar cutting forces are observed in LAM with sinusoidal laser scanning at only half of the laser power as that of linear laser scanning. However, due to the fluctuations in the cutting force for sinusoidal laser scanning, it can be recommended only for rough cuts in machining. The study demonstrates that through an appropriate selection of the laser parameters, the entire cutting zone can be heated to temperatures between 300-500 oC, desired in the machining of Ti6Al4V.

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A 3D FEM-based model of laser heating and machining for selection of process parameters and scanning path in laser-assisted machining of Ti6Al4V

Divse

Dubey

Marla

2022

Preprint

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“…DEFORM software is often used for 2D analysis of machining processes [5,6], but often also used for 3D simulation [7,8], or can be analyzed by special processes with advanced machining methods [9][10][11].…”

Section: Introductionmentioning

confidence: 99%

Finite Element Analysis of Tool Stresses, Temperature and Prediction of Cutting Forces in Turning Process

Necpal

Pokorný

Kuruc

2017

SSP

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The paper presents the simulation model of turning the process of C45 non-alloy steel with a tool made of carbide insert. A 3D final element model used a lagrangian incremental type and re-meshing chip separation criterion was experimentally verified by measure cutting forces using piezoelectric dynamometer. In addition, stresses and temperature in the tooltip were predicted and examine. This work could investigate failure the tooltip, which would be great interest to predict wear and damage of cutting tool.

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“…Zamini et al studied 3D simulation of laser assisted side milling of Ti6Al4V alloy using modified Johnson-cook material model. Effect of cutting velocity, laser power and tool wear on cutting force was studied with and without laser and found that are less than the milling without laser [3]. Shi et al studied numerical and experimental investigation of laser-assisted machining of Inconel 718.…”

Section: Introductionmentioning

confidence: 99%

Finite Element Method and Experimental Investigation of Hot Turning of Inconel 718

Parida¹,

Maity²

2016

AEF

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In the present work, a finite element modeling of hot turning has been carried out for predicting computationally the state variables like temperature distribution on chip surface and cutting forces in hot machining of Inconel 718. The hot turning operation has been carried out with L9 orthogonal design of experiment (DOE) with varying cutting speed, feed rate, heating temperature and constant depth of cut to analyze the responses. The model predicts the temperature distribution, cutting forces with and without heating. DEFORM 2D is applied for modeling hot turning simulation as similar as possible to the experimental result. Flow stress and input parameters should be modeled according to the actual machining conditions. The predicting results i.e. cutting forces and temperature distribution were partially validated with the experimental data.

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3D Simulation of Laser Assisted Side Milling of Ti6Al4V Alloy Using Modified Johnson-Cook Material Model

Cited by 8 publications

References 6 publications

A 3D FEM-based model of laser heating and machining for selection of process parameters and scanning path in laser-assisted machining of Ti6Al4V

A 3D FEM-based model of laser heating and machining for selection of process parameters and scanning path in laser-assisted machining of Ti6Al4V

Finite Element Analysis of Tool Stresses, Temperature and Prediction of Cutting Forces in Turning Process

Finite Element Method and Experimental Investigation of Hot Turning of Inconel 718

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