Finite Element Simulation of Segmented Chip Formation of Ti6Al4V

[+] Author and Article Information
Martin Bäker, Joachim Rösler, Carsten Siemers

Technical University of Braunschweig, Institut für Werkstoffe, Langer Kamp 8, D-38106 Braunschweig, Germany

J. Manuf. Sci. Eng 124(2), 485-488 (Apr 29, 2002) (4 pages) doi:10.1115/1.1459469 History: Received August 01, 2001; Online April 29, 2002
Copyright © 2002 by ASME
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The finite element model with a part of the chip already cut. A strong refinement leads to a high mesh density in the shear zone.
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Crack lines of the model for simulating segmented chips. (a) Crack line for the first crack. (b) Crack line for the second crack, introduced after the first segment has formed. The second crack begins to grow as soon as the line reaches the shear zone.
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Equivalent plastic strain after first crack begins to grow. There is a strong concentration of deformation along the crack sides and in front of the crack.
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Equivalent plastic strain for two later timesteps of the simulation. Top: After formation of the first crack. Bottom: After formation of the second crack. Deformation is strongly concentrated in the crack region.
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Equivalent plastic strain for a simulation with different crack configuration than that of the previous figures: The crack length is only one third of the chip thickness; the crack propagation speed was again chosen at 100 m/s. There is strong shear deformation along the upper crack flank.
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Temperature field [K] for the same timestep as in Fig. 5. Rapid plastic deformation occurs in front of the crack, leading to increasing temperature.
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Equivalent plastic strain for a simulation with same crack length as in Fig. 5; the crack propagation speed was reduced to 20 m/s. The shear deformation along the upper crack flank is even stronger, agreeing well with the experimentally produced chip in Fig. 8.
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Chip segments produced under orthogonal cutting conditions at cutting speed 20 m/s, cutting depth 0.085 mm, rake angle 0 deg. In the upper figure, strong plastic deformation on the shear edge is visible, in the lower figure, a crack with no visible deformation on the flank occurs.



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