Finite element analysis and modeling of temperature distribution in turning of titanium alloys

Reddy, Mohan M.; Kumar, Mohan; Shanmugam, Kumaraesan

doi:10.30544/323

Cited by 7 publications

(3 citation statements)

References 17 publications

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“…However, the effects of the tool geometry parameters on the residual stresses in the machined workpiece were not predicted. Reddy et al [26] utilized FE simulations to develop mathematical models of cutting forces and temperatures with respect to the cutting speed, feed rate, depth of cut, and tool edge radius during the dry turning of Ti-6Al-4V. They found that the feed rate and tool edge radius significantly affected cutting forces and temperatures.…”

Section: Introductionmentioning

confidence: 99%

The Influence of Tool Geometry Parameters on Thermo-Mechanical Loads and Residual Stresses Induced by Orthogonal Cutting of AA6061-T6: A Numerical Investigation

et al. 2023

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The residual stresses state that a mechanical part obtained after machining is a crucial factor that impacts its in-service performance. This stress state is influenced by the thermomechanical loads exerted on the parts during the machining process, which are, in turn, determined by the tool parameters, process, and machining conditions. The aim of the present research was to anticipate how the cutting tool’s edge radius, rake angle, and clearance angle would affect the forces, temperature, and residual stresses induced while orthogonally cutting aluminum AA6061-T6. To achieve this, two-dimensional DEFORM™ software was utilized to develop a finite element model. The residual stresses trend results obtained demonstrated that rake angles of 0° and 17.5–20° values with a small edge radius (5 to 10 µm) and clearance angles of 7 and 17.5° values gave higher compressive stresses. The obtained simulated results were in good agreement with the experiments. The cutting forces, the temperature, and the maximum and minimum machining-induced residual stresses were found to be influenced more by the tool edge radius and the tool rake angle. The influence of the clearance angles on the above-mentioned machining responses was the least. Residual stresses can have a significant impact on the in-service performance of machined parts. The obtained results will help engineers select or design tools that promote a desired surface integrity during machining. This task is not obvious in practice because of difficulties in measuring residual stresses and also because the machining parameters and the tool geometry parameters have different and opposite impacts on thermo-mechanical loads, productivity, and on machining induced residual stresses.

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Section: Introductionmentioning

confidence: 99%

The Influence of Tool Geometry Parameters on Thermo-Mechanical Loads and Residual Stresses Induced by Orthogonal Cutting of AA6061-T6: A Numerical Investigation

et al. 2023

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“…This method provides support for the research on chip formation, cutting temperature prediction, microstructure evolution, cutting force and residual stress [21][22][23]. In addition, finite element technology has become an indispensable means to study the cutting mechanism of titanium alloys [24][25][26][27][28][29][30][31][32]. Davim et al [23] integrated many of the relevant aspects in the development of coolant assisted finite element method (FEM) simulations applied in difficult-to-cut materials, including titanium alloy.…”

Section: Introductionmentioning

confidence: 99%

“…Davim et al [23] integrated many of the relevant aspects in the development of coolant assisted finite element method (FEM) simulations applied in difficult-to-cut materials, including titanium alloy. Moola et al [25] applied the finite element model to the machinability of Ti-6Al-4V in dry cutting environment using cubic boron nitride and a polycrystalline diamond tool. Naresh et al [26] proposed the application of elastoplastic model based on explicit finite element analysis to simulate the erosion behavior of titanium alloys in abrasive water jet machining.…”

Section: Introductionmentioning

confidence: 99%

Influence of cutting velocity on surface roughness during the ultra-precision cutting of titanium alloys based on a comparison between simulation and experiment

Lou

Chen

et al. 2023

PLoS ONE

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The Ti-6Al-4V titanium alloy is a kind of light alloy material with high specific strength, corrosion resistance and heat resistance. Because of its excellent performance, it has become an important material in aerospace industry. However, this kind of alloy has very poor machinability, and rapid tool wear is a very serious problem in titanium alloy processing. At present, it is difficult to guarantee the ultra-precision machining quality of titanium alloy materials, which limits its application in high-tech fields. In order to solve this problem, the influence of cutting speed on ultra-precision cutting process of titanium alloy was analyzed comprehensively. and it was found that better surface quality could be obtained at lower cutting speed. In order to study the influence of cutting speed in ultra-precision cutting of titanium alloys, cutting experiments have been carried out. Additionally, a finite element model was established to analyze the ultra-precision cutting process. Also, the constitutive model, damage model, friction model, and heat transfer in the modeling process were discussed. The chip morphology, cutting temperature, cutting force, and surface morphology under different cutting velocities are analyzed by simulation. Then, the simulation results were compared with the experimental results. The findings show that cutting speed has great influence on the ultra-precision turning of the Ti-6Al-4V alloy and the surface roughness obtained by ultra-precision cutting of titanium alloy can be lower than 20 nm at a lower cutting speed.

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On the impacts of tool geometry and cutting conditions in straight turning of aluminum alloys 6061-T6: an experimentally validated numerical study

Javidikia

Sadeghifar

Songmené

et al. 2020

Int J Adv Manuf Technol

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Aluminum alloys 6061-T6 are widely utilized in the automotive, aerospace and marine industries due to high corrosion resistance, high strength, and good workability and machinability. The machining performance of these alloys depend on several factors including tool's material, coating and geometry.Cutting tool edge radius is one of the most effective factors in cutting forces, energy requirement and chip formation during metal cutting. The present article aims to study the interactions between the cutting edge radius and cutting speed, feed rate and rake angle and examine the impacts of the aforementioned tool geometry and cutting conditions on machining forces, cutting temperature, and chip thickness in cutting an aluminum alloy 6061-T6. Special attention is devoted to examining the influence of the cutting edge radius on machining variables and comparing the results of conventional machining (CM) and high speed machining (HSM). A finite element model was developed to simulate the above intercations and was experimentally validated for different machining parameters. The results demonstrate that although increasing the cutting edge radius clearly raises the machining forces, it has a slight influence on the chip thickness. It is also found that the maximum cutting temperatures remain nearly constant with changes in the tool edge radius, while the average temperatures of the tool tip increase especially in HSM. Furthermore, it was found that the location at which the maximum cutting temperature occurs depends more on cutting conditions and tool geometry than workpiece and tool materials.

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Finite element analysis and modeling of temperature distribution in turning of titanium alloys

Cited by 7 publications

References 17 publications

The Influence of Tool Geometry Parameters on Thermo-Mechanical Loads and Residual Stresses Induced by Orthogonal Cutting of AA6061-T6: A Numerical Investigation

The Influence of Tool Geometry Parameters on Thermo-Mechanical Loads and Residual Stresses Induced by Orthogonal Cutting of AA6061-T6: A Numerical Investigation

Influence of cutting velocity on surface roughness during the ultra-precision cutting of titanium alloys based on a comparison between simulation and experiment

On the impacts of tool geometry and cutting conditions in straight turning of aluminum alloys 6061-T6: an experimentally validated numerical study

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