Serrated chip formation mechanism analysis for machining of titanium alloy Ti-6Al-4V based on thermal property

Zang, Jianbing; Zhao, Jun; Li, Anhai; Pang, Jiming

doi:10.1007/s00170-017-0451-6

Cited by 40 publications

(19 citation statements)

References 23 publications

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“…According to Zang et al (Zang et al 2017), the machining of the Ti6Al4V alloy was followed by a pronounced temperature rise in the workpiece and the cutting tool, due to the significant workpiece material deformations and the high levels of friction. To take into account these thermomechanical coupling conditions, 100% of the energy generated by the friction work was assumed converted to a heat flow (Eq.…”

Section: Heat Transfer Modelingmentioning

confidence: 99%

“…In this study, the commonly used 4-node quadrilateral bilinear elements CPE4RT, available in the Abaqus2D®/Explicit library, were defined when the ALE approaches and the pure Lag formulation were adopted. These continuum quadrangular elements have been widely used in the literature to model the 2D FEM of the orthogonal machining (Liu et al, 2013;Mabrouki et al, 2008;Miguélez et al, 2006;Miguèlez et al, 2013;Molinari et al, 2012;Saleem et al, 2016;Zang et al 2017;. A reduced integration was used by these elements.…”

Section: Numerical Modelsmentioning

confidence: 99%

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A 2D finite element analysis of the effect of numerical parameters on the reliability of Ti6Al4V machining modeling

Yaich

Ayed

Bouaziz

et al. 2020

Machining Science and Technology

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HAL is a multi-disciplinary open access archive for the deposit and dissemination of scientific research documents, whether they are published or not. The documents may come from teaching and research institutions in France or abroad, or from public or private research centers. L'archive ouverte pluridisciplinaire HAL, est destinée au dépôt et à la diffusion de documents scientifiques de niveau recherche, publiés ou non, émanant des établissements d'enseignement et de recherche français ou étrangers, des laboratoires publics ou privés.

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Section: Heat Transfer Modelingmentioning

confidence: 99%

Section: Numerical Modelsmentioning

confidence: 99%

A 2D finite element analysis of the effect of numerical parameters on the reliability of Ti6Al4V machining modeling

Yaich

Ayed

Bouaziz

et al. 2020

Machining Science and Technology

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“…A serrated or segmented chip (also named as a "saw-tooth" chip) generally occurs during the cutting of Ti6Al4V alloy. The segmented chips could be generated at lower cutting speeds and are more clearly seen at high cutting speeds [13]. Theoretically, the segmented chip generation is due to the thermoplastic uncertainty concentrated in adiabatic shear bands and the crack initiation in the primary shear zone.…”

Section: Introductionmentioning

confidence: 99%

Analytical, FEA, and experimental research of 2D-Vibration Assisted Cutting (2D-VAC) in titanium alloy Ti6Al4V

Kurniawan

Ahmed

Ali

et al. 2021

Int J Adv Manuf Technol

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In the 2D-Vibration Assisted Cutting (2D-VAC) method, the cutting tool shakes in a 2-dimensional approach because of superimposed high-frequency modulation. This high-frequency modulation effect creates a displacement at a tiny scale of micrometers and causes an escalation in the resultant cutting speed. Consequently, 2D-VAC has superior advantages compared to traditional cutting (TC). This manuscript describes research on 2D-VAC that focuses on modeling cutting forces (mathematical model) and finite element analysis (FEA) results. The FEA results are focused on the von Mises stress, plastic strain, cutting force, cutting temperature, and residual stress. In addition, an experiment for the chip formation, microstructure layer, and micro-hardness was also analyzed in this study. According to the modeling results, the cutting force has a comparable pattern to the FEA results. The stress contour result confirms that the 2D-VAC method has lower stress than that in the TC method during tool retraction mode. Additionally, the plastic strain in the 2D-VAC method can be higher than that in the TC method. According to the temperature results, the peak temperature in the 2D-VAC could be higher than that in the TC method. The residual stress shows that there is a compressive effect. Thus, the compressive stress is higher than that in the TC method. Micro-hardness results confirmed that there is not too much change from the original surface in the 2D-VAC method. The result of micro-structure morphology also confirmed that there is a significant shear deformation flow in case of the TC method, although less occurs in the 2D-VAC method.

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“…Oliaei and Karpat investigated the effect of friction conditions on FE simulation of micro-scale machining with the presence of a built-up edge [16]. Zang investigated the effect of thermal conductivity on the degree of chip segmentation and the adiabatic shear localization using ABAQUS/Explicit [17]. They found that as thermal conductivity increases, the degree of adiabatic shear decreases.…”

Section: Introductionmentioning

confidence: 99%

Finite Element Simulation of the Machining Process of Boiling Structures in a Novel Radial Heat Sink for High-Power LEDs

et al. 2020

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A phase change heat sink has higher heat transfer efficiency compared to a traditional metal solid heat sink, and is thus more preferred for the heat dissipation of high-power light-emitting diodes (LEDs) with very high heat flux. The boiling structure at the evaporation surface is the biggest factor that affects heat sink resistance. It is necessary to investigate the plastic deformation law during the machining process of boiling structures. In this study, a novel phase change radial heat sink was developed for high-power LED heat dissipation. First, a working principle and a fabrication process for the heat sink were introduced. Subsequently, to achieve an excellent heat dissipation performance, the machining process of boiling structures was numerically simulated and investigated. To be specific, plastic deformation generated during the formation was analyzed, and key parameters related to the morphology of the boiling structures were discussed including feeding angles and machining depths. Moreover, the finite element (FE) simulation results were compared with those of experiments. Last but not least, the heat transfer performance of the fabricated heat sink was tested. Results showed that the developed heat sink was well suited for a high-power LED application.

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Serrated chip formation mechanism analysis for machining of titanium alloy Ti-6Al-4V based on thermal property

Cited by 40 publications

References 23 publications

A 2D finite element analysis of the effect of numerical parameters on the reliability of Ti6Al4V machining modeling

A 2D finite element analysis of the effect of numerical parameters on the reliability of Ti6Al4V machining modeling

Analytical, FEA, and experimental research of 2D-Vibration Assisted Cutting (2D-VAC) in titanium alloy Ti6Al4V

Finite Element Simulation of the Machining Process of Boiling Structures in a Novel Radial Heat Sink for High-Power LEDs

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