Phenomenological study of chip flow/formation and unified cutting force modelling during Ti6Al4V alloy turning operations

Cherif, Iheb; Dorlin, Théo; Marcon, Bertrand; Fromentin, Guillaume; Karaouni, Habib

doi:10.1016/j.procir.2018.09.033

Cited by 4 publications

(4 citation statements)

References 9 publications

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“…(1). This formulation displays convincing correlation with experimental tests in Chérif's study when the inclination angle is equal to zero Chérif et al (2018). Finally, the effect of the cutting speed is added to the model by multiplying f v and f h by a dimensionless term V c /V o raised to a certain power (n v and n h ) where V o = 52.5 m/min.…”

Section: Local Forces Model and Edge Discretisation Methodologymentioning

confidence: 55%

“…So the global forces are expressed as A + B(t) where A is the cutting force level when the tool is fresh and B (t) represents the force increase due to wear over time. The f o component is untouched as chip flow direction is unaffected by tool wear according to experimental observations in similar conditions (Chérif et al (2018)). Considering constant lubrication conditions, cutting speed is the most influent process parameter on tool life followed by feed and depth of cut.…”

Section: Formulation Of the Modelmentioning

confidence: 73%

“…tangential to the cutting edge. Following this idea, Dorlin et al (2016) and Chérif et al (2018), with a mechanistic approach, completed the original local force model used by Armarego and Whitfield (1985) by adding a third local force tangent to the cutting edge. It allows better prediction of cutting forces when machining with round insert or with the tool nose.…”

Section: Introductionmentioning

confidence: 99%

See 2 more Smart Citations

Machinability of inconel 718 during turning: Cutting force model considering tool wear, influence on surface integrity

Toubhans

Fromentin

Viprey

et al. 2020

Journal of Materials Processing Technology

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Machining accuracy can be compromised by elastic workpiece deformation and subsurface residual stress introduction during cutting. In order to anticipate the impact of cutting forces and surface integrity evolutions on finished surface and its geometrical errors, it is necessary to better understand the influence of cutting conditions and tool wear. In this study, machinability of Inconel 718 using a round carbide tool in finish turning conditions is assessed. Cutting forces evolution during tool life are analysed and accompanied by advanced investigations of cutting phenomena. An original mechanistic cutting force model is developed, identified and tested. It includes the effect of tool wear over time in its local formulation. This model allows predicting cutting forces evolution along tool pass for a wide range of finishing cutting conditions. Furthermore, a thorough analysis of residual stress profiles at different tool wear levels is led. It features quantitative results for fresh and worn tools. A study on the influence of cutting parameters and tool wear on residual stress profiles in the machining affected zone is highlighted.

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Section: Local Forces Model and Edge Discretisation Methodologymentioning

confidence: 55%

Section: Formulation Of the Modelmentioning

confidence: 73%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Machinability of inconel 718 during turning: Cutting force model considering tool wear, influence on surface integrity

Toubhans

Fromentin

Viprey

et al. 2020

Journal of Materials Processing Technology

Self Cite

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show abstract

“…The cutting forces variations are highly related with the chip formation procedures. 20 The adaptions of the cutting forces under different tool inclination angles when side milling the thin-walled workpieces are further investigated based on the chip formations by using the FE simulations. Here, the time-varying procedures of the chip formation under the condition of θ = 20° are given for ease of explanation (see Figure 11).…”

Section: Cutting Forces Adaption Based On Tool Inclination Anglementioning

confidence: 99%

Parametric study on the tool inclination angle for side milling thin-walled workpiece edges based on finite element simulation

Liu

Dang

et al. 2019

Proceedings of the Institution of Mechanical Engineers, Part B:

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Side milling thin-walled workpiece edges is an indispensible procedure in the continuous process chains for the high-efficiency machining of thin-walled functional parts, for example, the small- and medium-sized compressor blades. In these operation cases, the workpiece vibration is easy to occur due to the poor stiffness of the thin-walled structures, causing defects to the machined surface finish and even the dimensional accuracy of the thin-walled workpiece edges. To this problem, this study proposes the tool inclination method based on the adaption of the cutting force component in the lowest stiffness direction of the thin-walled workpiece, and it aims, first, to guarantee the machined surface finish which is mostly dominated by the workpiece vibrations mainly induced by the relatively high cutting forces and, second, to guarantee the high machining efficiency. The parametric study on the tool inclination angle for side milling the thin-walled workpiece edges was conducted by using the finite element simulations. First, the finite element models were elaborated and validated by the experimental results in terms of the cutting forces. Then, based on a series of finite element simulations, the effects of the tool inclination angle on the cutting forces adaption and its corresponding mechanism, that is, the chip formation variation, were investigated. Simulation results under the given conditions showed that the optimal tool inclination angle for the minimum absolute value of Fn was 26°. At last, the prediction feasibility for the best machined surface finish when side milling the low-stiffness thin-walled workpiece edges at the optimal tool inclination angle was well validated by the experimental results. The proposed tool inclination method with the solid end mill based on the finite element model to improve the machined surface finish is meaningful and feasible for the high-efficiency manufacturing processes of thin-walled workpieces.

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Prediction of form error during face turning on flexible Inconel 718 workpiece

et al. 2019

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Phenomenological study of chip flow/formation and unified cutting force modelling during Ti6Al4V alloy turning operations

Cited by 4 publications

References 9 publications

Machinability of inconel 718 during turning: Cutting force model considering tool wear, influence on surface integrity

Machinability of inconel 718 during turning: Cutting force model considering tool wear, influence on surface integrity

Parametric study on the tool inclination angle for side milling thin-walled workpiece edges based on finite element simulation

Prediction of form error during face turning on flexible Inconel 718 workpiece

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