Investigations on Mechanisms of Tool Wear in Machining of Ti-6Al-4V Using FEM Simulation

Zanger, Frederik; Schulze, Volker

doi:10.1016/j.procir.2013.06.082

Cited by 46 publications

(19 citation statements)

References 7 publications

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“…With reference to Equation (2), wear rate is an exponential function of temperature. Zanger [13] showed that in the Usui model, the sensitivity of wear rate to temperature was much higher than to contact pressure and velocity. Therefore, in Figure 14, the estimated wear rates have been plotted with respect to the corresponding temperature.…”

Section: Recommendation For Improvement In Wear Rate Estimation Durinmentioning

confidence: 99%

“…Combining the advantages of FEM and wear rate equations, researchers have attempted to develop physics-based methodologies for two dimensional [10][11][12][13] and three-dimensional tool wear predictions [14,15]. In all these wear prediction attempts, the cutting process with defined tool edge geometry was simulated with FEM until the mechanical and thermal loadings on the cutting tool reached steady state.…”

Section: Introductionmentioning

confidence: 99%

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A Unique Methodology for Tool Life Prediction in Machining

Hosseinkhani

2020

JMMP

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In this paper, a unique approach for estimating tool life using a hybrid finite element method coupled with empirical wear rate equation is presented. In the proposed approach, the computational time was significantly reduced when compared to nodal movement technique. However, to adopt such an approach, the angle between tool's rake and flank faces must be constant through the process and at least two cutting experiments need to be performed for empirical model calibration. It is also important to predict the sliding velocity along the tool/flank face interface accurately when using Usui's model to predict the tool wear rate. Model validations showed that when the sliding velocity was assumed to be equivalent to the cutting speed, poor agreement between the predicted and measured wear rate and tool life was observed, especially at low cutting speed. Furthermore, a new empirical model to predict tool wear rate in the initial or break-in period as a function of Von Mises stress field was developed. Experimental validation shows that the newly developed model substantially improved the initial tool wear rate in terms of trend and magnitude.

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Section: Recommendation For Improvement In Wear Rate Estimation Durinmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A Unique Methodology for Tool Life Prediction in Machining

Hosseinkhani

2020

JMMP

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“…The results show that with an increase in the friction coefficient, the friction becomes more severe and the cutting heat is increase [4]. Zanger and Schulze used the finite element method to analyse the stress field, temperature field and tool wear of the uncoated hard alloy cutting tool in the high-speed Ti-6Al-4V cutting process, and compared the results with the tool wear in the experiment so as to analyse the wear mechanism of the hard alloy cutting tool in the Ti-6Al-4V cutting process [5]. Zhang et al used finite element software to simulate the 3D multi-hardness assembling and milling process.…”

Section: Yang Zheng: Simulation and Analysis Of Ball-end Milling Of mentioning

confidence: 99%

Simulation and Analysis of Ball-End Milling of Panel Moulds Based on Deform 3D

Yang¹,

Zheng²

2017

Int. j. simul. model.

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Automobile panel moulds are assembled pieces with various surface features, making it difficult to predict the machining properties in ball-end milling process. In this paper, Deform 3D finite element analysis software is used to simulate the ball-end milling of multi-hardness assembled moulds, and to analyse the distribution patterns of milling forces, stress fields and temperature fields in the transition regions of the multi-hardness assembled moulds. Subsequently, milling of sine surface moulds is simulated, and the effects of milling parameters on the thermal performance of sine surfaces are analysed. Finally, the multi-hardness assembling and milling experiment and the sine surface mould milling experiments are conducted to verify the effectiveness of the Deform 3D finite element simulation method.

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“…The latter mechanism can be considered rate-limited by temperature according to a model by Usui et al [4]. A corresponding wear mechanism with an Archard-type, exponential, temperature dependence has been specifically considered for Ti6Al4V by Zanger and Schulze [5].…”

Section: Introductionmentioning

confidence: 99%

Experimental Study of Wear Mechanisms of Cemented Carbide in the Turning of Ti6Al4V

et al. 2019

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Titanium and titanium alloys such as Ti-6Al-4V are generally considered as difficult-to-machine materials. This is mainly due to their high chemical reactivity, poor thermal conductivity, and high strength, which is maintained at elevated temperatures. As a result, the cutting tool is exposed to rather extreme contact conditions resulting in plastic deformation and wear. In the present work, the mechanisms behind the crater and flank wear of uncoated cemented carbide inserts in the turning of Ti6Al4V are characterized using high-resolution scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and high-resolution Auger electron spectroscopy (AES).The results show that, for combinations of low cutting speeds and feeds, crater and flank wear were found to be controlled by an attrition wear mechanism, while for combinations of medium to high cutting speeds and feeds, a diffusion wear mechanism was found to control the wear. For the latter combinations, high-resolution SEM and AES analysis reveal the formation of an approximately 100 nm thick carbon-depleted tungsten carbide (WC)-layer at the cemented carbide/Ti6Al4V interface due to the diffusion of carbon into the adhered build-up layers of work material on the rake and flank surfaces.

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Investigations on Mechanisms of Tool Wear in Machining of Ti-6Al-4V Using FEM Simulation

Cited by 46 publications

References 7 publications

A Unique Methodology for Tool Life Prediction in Machining

A Unique Methodology for Tool Life Prediction in Machining

Simulation and Analysis of Ball-End Milling of Panel Moulds Based on Deform 3D

Experimental Study of Wear Mechanisms of Cemented Carbide in the Turning of Ti6Al4V

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