2134/26443
Wei Bai
Wei
Bai
Ronglei Sun
Ronglei
Sun
Anish Roy
Anish
Roy
Vadim Silberschmidt
Vadim
Silberschmidt
Improved analytical prediction of chip formation in orthogonal cutting of titanium alloy Ti6Al4V
Loughborough University
2017
Orthogonal cutting
Chip formation
Analytical model
Chip segmentation
Titanium alloy
Mechanical Engineering not elsewhere classified
Mechanical Engineering
2017-09-11 13:13:52
Journal contribution
https://repository.lboro.ac.uk/articles/journal_contribution/Improved_analytical_prediction_of_chip_formation_in_orthogonal_cutting_of_titanium_alloy_Ti6Al4V/9572843
The aim of this paper is to propose an analytical model of chip formation for
precise prediction of orthogonal cutting of Ti6Al4V. This alloy is used broadly in
aerospace components; hence, prediction of thermomechanical parameters of its
orthogonal cutting is crucial for various industrial applications. The suggested analytical
model needs only cutting parameters and tool geometry as input; it can predict not only
cutting forces but also main features of a primary shear zone and a tool-chip interface. A
non-equidistant shear zone model is employed to calculate shear strains and a shear
strain rate in the primary shear zone, and a simplified heat-transfer equation is used for
temperature. A Calamaz-modified Johnson-Cook material model that accounting for
flow softening at high strains and temperature-dependent flow softening is applied to
assess shear stresses in the primary shear zone. In addition, a shear-angle solution is
modified for Ti6Al4V. At the tool-chip interface, a contact length, equivalent strain and
an average temperature rise are defined. Besides, the effect of sliding and apparent
friction coefficients is investigated. For a sawtooth chip produced in the cutting process
of Ti6Al4V, the segmented-chip formation is analysed. A chip-segmentation frequency
and other parameters of the sawtooth chip are also obtained. The predicted results are
compared with experimental data with the cutting forces, tool-chip contact length, shear
angle and chip-segmentation frequency calculated with the developed analytical model
showing a good agreement with the experiments. Thus, this analytical model can
elucidate the mechanism of the orthogonal cutting process of Ti6Al4V including
predictive capability of continuous and segmented chip formation.