Influence of different cutting edges caused by tool wear on cutting process of titanium alloy TC21 based on finite element model

Abstract

Titanium alloys have emerged as a significant aerospace material due to the high strength, good corrosion resistance and high temperature resistance thereof, but such alloys also have poor machinability because of the unique properties. Rapid tool wear is a serious problem for titanium alloy machining, with tool wear resulting in different tool edges. In the present study, finite element technology was used to establish a 2D cutting numerical model, so as to investigate the influence of the different cutting edges caused by tool wear during the machining process of titanium alloy TC21. In the cutting model, four different types of tool edges, including sharp edge, round edge, chamfer edge and crater edge, were established to analyze the influence of different tool edges on the cutting process of TC21 alloy. Additionally, the material model, chip separation model, friction model and heat transfer model have been included in the established model. A series of cutting simulations based on the model were conducted, through which the chip morphology, cutting temperature, cutting force, surface morphology and residual stress under the different tool edges were analyzed. The simulation results were compared with the experimental results, and indicated that the tool edge is a significant factor in the machining process of TC21 alloy. A proper cutting edge can improve the cutting quality.

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

“…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.…”

Finite element modeling of high-speed orthogonal cutting: A contribution to understanding the influence of mesh parameters on saw-toothed chip formation

“…Many researches have been conducted to study the phenomenon of saw-toothed chip formation based on the FE analysis of cutting process. 23–26 It has been found that the accuracy of these analyses is highly dependent on mesh parameters. In chip formation simulations, the influence of mesh parameters has been examined to decrease mesh dependence.…”