Development of a multi-scale and coupled cutting model for the drilling of Ti-6Al-4V

Bonnet, Camille; Pottier, Thomas; Landon, Yann

doi:10.1016/j.cirpj.2021.08.007

Cited by 14 publications

(3 citation statements)

References 52 publications

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“…Numerous studies have been concerned with modeling the drilling process to determine optimal machining modes (see, for example, [25][26][27]), kinetic characteristics of the process (see, for example, [28][29][30][31]), and mechanical characteristics of the machined material (see, for example, [32][33][34]). Some researchers have paid special attention to modeling drilling processes with different types of tools for hard-to-machine materials (see, for example, [35][36][37][38]), particularly titanium [39,40] and nickel [41,42] alloys.…”

Section: Methods For the Determination Of Thermal Characteristics In ...mentioning

confidence: 99%

“…The tool temperature values measured with an infrared camera were used to verify the model. Bonnet et al developed a finite element model for drilling Ti-6Al-4V titanium alloy with carbide twist drills [40] to calculate heat flows and the energy balance in the cutting zones. A numerical-experimental method was used to quantitatively determine the thermal and mechanical loads of the machined material.…”

Section: Methods For the Determination Of Thermal Characteristics In ...mentioning

confidence: 99%

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Numerical Modeling of Cutting Characteristics during Short Hole Drilling: Part 2—Modeling of Thermal Characteristics

Storchak,

Stehle,

Möhring

2024

JMMP

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The modeling of machining process characteristics and, in particular, of various cutting processes occupies a significant part of modern research. Determining the thermal characteristics in short hole drilling processes by numerical simulation is the object of the present study. For different contact conditions of the workpiece with the drill cutting inserts, the thermal properties of the machined material were determined. The above-mentioned properties and parameters of the model components were established using a three-dimensional finite element model of orthogonal cutting. Determination of the generalized values of the machined material thermal properties was performed by finding the set intersection of individual properties values using a previously developed software algorithm. A comparison of experimental and simulated values of cutting temperature in the workpiece points located at different distances from the drilled hole surface and on the lateral clearance face of the drill outer cutting insert shows the validity of the developed numerical model for drilling short holes. The difference between simulated and measured temperature values did not exceed 22.4% in the whole range of the studied cutting modes.

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Section: Methods For the Determination Of Thermal Characteristics In ...mentioning

confidence: 99%

Section: Methods For the Determination Of Thermal Characteristics In ...mentioning

confidence: 99%

Numerical Modeling of Cutting Characteristics during Short Hole Drilling: Part 2—Modeling of Thermal Characteristics

Storchak,

Stehle,

Möhring

2024

JMMP

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“…In the study by Muhammad et al [35], the numerical modeling of the titanium alloy drilling process was carried out with an additional energy input by means of heating the machined material to reduce its strength during the cutting process. Bonnet et al presented a mixed numerical experimental approach to verify the multi-scale numerical model they developed [36]. This model ensured a more accurate determination of thermomechanical loads during the drilling of titanium alloys.…”

Section: Methods For the Determination Of Kinetic Characteristics In ...mentioning

confidence: 99%

Numerical Modeling of Cutting Characteristics during Short Hole Drilling: Modeling of Kinetic Characteristics

Storchak,

Stehle,

Möhring

2023

JMMP

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Analyzing the cutting process characteristics opens up significant opportunities to improve various material machining processes. Numerical modeling is a well-established, powerful technique for determining various characteristics of cutting processes. The developed spatial finite element model of short hole drilling is used to determine the kinetic characteristics of the machining process, in particular, the components of cutting force and cutting power. To determine the component model parameters for the numerical model of drilling, the constitutive equation parameters, and the parameters of the contact interaction between the drill and the machined material on the example of AISI 1045 steel machining, the orthogonal cutting process was used. These parameters are determined using the inverse method. The DOE (Design of Experiment) sensitivity analysis was applied as a procedure for determining the component models parameters, which is realized by multiple simulations using the developed spatial FEM model of orthogonal cutting and the subsequent determination of generalized values of the required parameters by finding the intersection of the individual value sets of these parameters. The target values for the DOE analysis were experimentally determined kinetic characteristics of the orthogonal cutting process. The constitutive equation and contact interaction parameters were used to simulate the short hole drilling process. The comparison of experimentally determined and simulated values of the kinetic characteristics of the drilling process for a significant range of cutting speed and drill feed changes has established their satisfactory coincidence. The simulated value deviation from the corresponding measured characteristics in the whole range of cutting speed and drill feed variation did not exceed 23%.

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Investigating hole making performance of Al 2024-T3/Ti-6Al-4V alloy stacks: A comparative study of conventional drilling, peck drilling and helical milling

Feist

Elmore

et al. 2022

Int J Adv Manuf Technol

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This work reports a comparative study on different hole making methods, namely conventional drilling, peck drilling and helical milling, for Al 2024-T3/Ti-6Al-4V stacks in aircraft applications. The impacts of different hole making methods with constant or varied machining parameters across the stacked structures have been investigated. The resulting exit burr, hole surface roughness/microstructural change and fatigue behaviour of the machined stacks have been characterized in detail. Results show that the exit burr formation is most severe for conventional drilling and least burr is produced in helical milling coupons. Deploying varying parameters (i.e. optimal parameters for each individual metal layer) across the stacks can effectively reduce the burr formation in conventional drilling and peck drilling. 3D surface morphology shows that Al 2024-T3 hole surface contains multiple scratches and trenches, while Ti-6Al-4V hole surface features regular feed marks. Helical milling leads to the highest Al 2024-T3 hole surface roughness, which can be attributed to the abrasion caused by the evacuated Ti-6Al-4V chips. Sub-surface microstructural analysis shows that the Ti-6Al-4V layer is more prone to machining-induced microstructural change (i.e. white layer formation and/or grain plastic deformation along machining direction). The relatively low fatigue performance of stacks produced by conventional drilling and peck drilling with constant parameters can be related to the presence of the brittle Ti-6Al-4V white layer in these coupons. Deploying varied parameters across stacks in conventional drilling and peck drilling can effectively eliminate Ti-6Al-4V white layer formation and improve the stacks fatigue life by 72% and 38%, respectively. Helical milling leads to the longest stack fatigue life (~ 100% and 40% greater than conventional drilling and peck drilling, respectively).

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Development of a multi-scale and coupled cutting model for the drilling of Ti-6Al-4V

Cited by 14 publications

References 52 publications

Numerical Modeling of Cutting Characteristics during Short Hole Drilling: Part 2—Modeling of Thermal Characteristics

Numerical Modeling of Cutting Characteristics during Short Hole Drilling: Part 2—Modeling of Thermal Characteristics

Numerical Modeling of Cutting Characteristics during Short Hole Drilling: Modeling of Kinetic Characteristics

Investigating hole making performance of Al 2024-T3/Ti-6Al-4V alloy stacks: A comparative study of conventional drilling, peck drilling and helical milling

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