Investigation of the turning process of the TC21 titanium alloy: Experimental analysis and 3D simulation

Abstract

Titanium alloys are widely used in the aerospace industry due to their superior properties such as high strength and low density. As a new titanium alloy with higher strength and lower heat conductivity, titanium alloy TC21 is very difficult to cut and the cutting mechanism of this alloy needs to be investigated deeply. In the paper, to observe the cutting phenomenon in the turning process of TC21 alloy, a series of turning experiments have been performed to investigate the turning process of TC21 alloy. Further, the influence of some important turning parameters (cutting speed, feed speed, depth of cut and rake angle) on cutting force and chip morphology is well analyzed through the experiments. In addition, a 3D finite element model for turning was established using the software ABAQUS for helping to analyze the turning process of TC21. Through simulation, cutting force, chip formation and temperature distribution of TC21 alloy in the turning process have been achieved. At the same time, simulated cutting forces and chip morphology were compared with the results of experiment. The results of experiments showed that the chip of TC21 alloy in turning process is serrated and the rake angle of tool has the obvious effect on the chip morphology.

Cutting mechanics and efficiency of forward and reverse multidirectional turning

“…Where the second deformation zone produces the largest frictional force, the friction is severe. The second deformation zone can be further divided into sliding and sticking zones [41]. As shown in Fig.…”

“…For example, an orthogonal cutting finite element model was established in ABAQUS, and the effects of cutting parameters on the performance of machined parts and their interactions were analyzed using ANOVA [40]. Similarly, a finite element model was established by ABAQUS to obtain the cutting force, chip formation and cutting temperature distribution of TC21 alloy during the cutting process [41]. The formation process of chips in AISI 4140 cutting and the process forces generated were investigated through 2D model and 3D model FEM simulations.…”

A Fuzzy Logic Model for the Analysis of Ultrasonic Vibration Assisted Turning and Conventional Turning of Ti-Based Alloy

“…Simulation tools allow readers to obtain the required results without spending time on costly and time-consuming experimental techniques. Many two- and three-dimensional finite element (FE) models have been developed for the orthogonal turning of Ti alloys to examine the outcomes of materials at several machining input parameters [ 15 , 16 , 17 , 18 ]. Similarly, with advances in computational facilities and software, three-dimensional FE simulation models have been established for conventional and assisted oblique turning processes [ 7 , 19 ].…”