Computational Machining of Titanium Alloy—Finite Element Modeling and a Few Results

[+] Author and Article Information
T. Obikawa

Department of Mechano-Aerospace Engineering, Tokyo Institute of Technology, 2-12-1 Ohokayama, Meguro-ku, Tokyo 152, Japan

E. Usui

Department of Mechanical Engineering, Tokyo Denki University, 2-2 Kanda-nishikicho, Chiyoda-ku, Tokyo 101, Japan

J. Manuf. Sci. Eng 118(2), 208-215 (May 01, 1996) (8 pages) doi:10.1115/1.2831013 History: Received June 01, 1993; Revised December 01, 1994; Online January 17, 2008


A Finite element modeling was developed for the computational machining of titanium alloy Ti-6Al-4V. The chip formation in metal cutting is one of the large deformation problems, thus, in the formulation of the elastic-plastic deformation analysis, geometrical nonlinearity due to the large shape change of the finite elements was taken into account and the over-constraint of incompressibility on the deformation of ordinary finite elements in the plastic range was relaxed to make the elements deformable as a real continuum. A ductile fracture criterion on the basis of strain, strain rate, hydrostatic pressure and temperature was applied to the crack growth during the chip segmentation. The temperature field in the flowing chip and workpiece and the fixed tool was calculated simultaneously by an unsteady state thermal conduction analysis and the remeshing of tool elements. The serrated chips predicted by the computational machining showed striking resemblances in the shape and irregular pitch of those obtained by actual cutting. The mean cutting forces and the amplitude of cutting force vibration in the computational machining were in good agreement with those in the actual machining.

Copyright © 1996 by The American Society of Mechanical Engineers
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