Numerical Modeling of Titanium Alloy Ti10V2Fe3Al Milling Process

Abstract

The simulation of material machining using finite element models is a powerful tool for the optimization of simulated processes and tools, as well as for the determination of cutting process characteristics that are difficult or practically impossible to determine by experiment. The paper presents results of the numerical simulation of the titanium alloy Ti10V2Fe3Al (Ti-1023). The behavior of the machined material was modeled with the Johnson–Cook constitutive equation, and its damage mechanism was modeled using the Cockcroft and Latham model. The parameters of the constitutive equation for machined material behavior and damage were determined using a DOE sensitivity analysis during orthogonal cutting. The values of the cutting force components, as well as the minimum and maximum chip thicknesses, were used as target functions for the DOE analysis. The generalized values of the constitutive equation parameters and the fracture stress values determined by the DOE analysis were calculated as the set intersection of individual multitude values of these parameters. The simulation results of the studied cutting processes showed an acceptable agreement with the experimental data when the cutting speed and tool feed changed significantly. The deviation in the simulated values of the cutting forces from their measured values ranged from about 10% to about 20%.

Generation of Mechanical Characteristics in Workpiece Subsurface Layers through Milling

“…In this case, the volume V m was determined from the nominal chip shape, without taking chip compression into account. This assumption was made on the basis that the chip compression ratio of the used Ti-1023 titanium alloy for the studied range of cutting modes does not exceed 1.1 [84,86]. The effect of cutter feed and cutting speed on the cutting work A cf is presented exemplarily for a cutting speed V C = 60 m/min and a radial depth of cut a e = 1.5 mm in Figure 9.…”

“…The description of the experimental setup, the measurement equipment for the cutting force and torque components, the used tool (carbide end cutter) and its geometrical parameters, and the initial geometry of the machined workpiece (tested specimens) are described in a previously published study [84]. Table 2 shows the mechanical and thermal properties of the carbide end cutter.…”

“…where V m is the material removal volume, and t s and t e are the simulation start and end times, respectively. A determination of the dependence function ( 4) was performed by simulating the milling process of the titanium alloy Ti-1023 workpiece (see Section 3.2) with an end cutter using the previously developed numerical model of the milling process [84,86]. The cutting tool in these models was modeled as a perfectly rigid body and the workpiece material as an isotropic material defined by the Johnson-Cook constitutive equation [93,94].…”

“…The fracture mechanism of the machined material [97] was realized using the Cockcroft and Latham model [98]. The critical stress value of the Cockcroft and Latham model as well as the parameters of the constitutive equation were found through sensitivity analysis by DOE (Design of Experiment) [84,86].…”

Experimental Procedure to Study the High Speed Orthogonal Cutting of Unidirectional GFRP

“…Theoretical models and experimental applications on orthogonal cutting are essential for understanding the fundamental principles of more complex machining processes such as drilling and milling [1][2][3]. By analysing cutting forces in simple models, it is possible to identify factor influencing material removal, tool wear, and surface quality.…”