Calculation of Contact Stresses during Titanium Alloy Cutting

Abstract

The paper presents data about distribution of contact stresses on a rake surface and flank-land of a cutter in free orthogonal turning of a disk made from a titanium alloy (Ti-6Al-2Mo-2Cr). On the cutting edge of the bar blade, there is a normal force Nρ, directed perpendicularly to a transient surface, with a large magnitude of specific linear force qN r= 182.6 N/mm, but the tangential force on the cutting edge Fρis equal to zero. On the rake surface, there are uniformly distributed shear contact stresses with very small magnitude of τ ≈ const ≈ 25 MPa, irrespective of feed rate, which speaks about plastic character of the contact on the rake surface. The greatest normal contact stress on the rake surface σmax≈ 1009 MPa, irrespective of feed rate. The greatest magnitude of normal contact stresses on the flank surface chamfer near the cutting edge σh max= 3400-2200 MPa confirms the hypothesis about recovery of a transient surface sag after separation of a formed element of a chip, and explains increased wear of the cutting tool on the flank surface at initial time. Normal σhand shear τhcontact stresses on the flank surface chamfer are essentially diminish with a distance from the cutting edge. It explains working ability of the cutting tool even at very large wear on the flank surface (hf> 3 mm). Our experimental data allows calculating the components of cutting force and contact stresses on the rake and flank surfaces of cutting tools during titanium alloy (Ti-6Al-2Mo-2Cr) machining.