Research Papers

Finite Element Modeling of Cutting Force and Chip Formation During Thermally Assisted Machining of Ti6Al4V Alloy

[+] Author and Article Information
Yao Xi

e-mail: y.xi@uq.edu.au

Michael Bermingham

e-mail: m.bermingham@uq.edu.au

Gui Wang

e-mail: gui.wang@uq.edu.au

Matthew Dargusch

e-mail: m.dargusch@uq.edu.au

Centre for Advanced Materials
Processing and Manufacture,
School of Mechanical and Mining Engineering,
The University of Queensland, St. Lucia,
Queensland 4072, Australia;
Defence Materials Technology Centre,
Hawthorn VIC3122, Australia

Manuscript received April 21, 2013; final manuscript received October 9, 2013; published online November 18, 2013. Assoc. Editor: Yung Shin.

J. Manuf. Sci. Eng 135(6), 061014 (Nov 18, 2013) (9 pages) Paper No: MANU-13-1176; doi: 10.1115/1.4025740 History: Received April 21, 2013; Revised October 09, 2013

The improvement in machinability during thermally assisted turning of the Ti-6Al-4V alloy has been investigated using finite element modeling. A 2D thermally assisted turning model was developed and validated by comparing the simulation results with experimental results. The effect of workpiece temperature on the cutting force and chip formation process was examined. The predicted cutting forces and chip morphologies from the simulation strongly correlated with the experimental results. It was observed from the simulation that the chip forms after the coalescence of two deformed regions in the shear band and that the cyclic cutting forces are strongly related to this chip formation process.

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Fig. 1

Three layers of the workpiece

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Fig. 3

Original cutting force data predicted by the 2D turning model for different workpiece preheating temperatures

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Fig. 4

Cutting force data comparison

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Fig. 5

Shear stress and cutting force

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Fig. 6

Shear stress in front of the cutting tool in the unit of Pa

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Fig. 7

Comparison between simulated chip formation and experimental chip. The contour shown in the simulation results is the equivalent plastic strain.

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Fig. 8

Chip measurement data comparison

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Fig. 9

History of chip formation: (a) equivalent plastic strain distribution at 7.0 × 10−6 s of cut, (b) temperature distribution at 7.0 × 10−6 s of cut, (c) equivalent plastic strain distribution at 9.7 × 10−6 s of cut, (d) equivalent plastic strain distribution at 1.0 × 10−6 s of cut. Cutting trial 1 simulation.

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Fig. 10

The evolution of multiple shear bands on chips, the contour is the distribution of equivalent plastic strain. States (a)–(f) correspond to the cutting forces (a)–(f) in Fig. 11.

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Fig. 11

Detailed cyclic cutting forces, cutting forces (a)–(f) correspond to the states (a)–(f) in Fig. 10




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