Influence of Constitutive Models and the Choice of the Parameters on FE Simulation of Ti6Al4V Orthogonal Cutting Process for Different Uncut Chip Thicknesses

Nithyaraaj Kugalur Palanisamy,Pedro-José Arrazola,François Ducobu,Edouard Rivière Lorphèvre

doi:10.3390/jmmp5020056

Nithyaraaj Kugalur Palanisamy, Pedro-José Arrazola + Show 2 more

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https://doi.org/10.3390/jmmp5020056

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Abstract

The constitutive model and its pertinent set of parameters are important input data in finite element modeling to define the behavior of Ti6Al4V during machining process. The present work focusses on comparing different constitutive models and the parameters sets available in literatures and investigating the quality of the predictions when varying uncut chip thickness (40 µm, 60 µm, 100 µm and 280 µm). In addition, temperature-dependent strain hardening factor along with strain softening phenomenon based reconstructed material model is proposed. The results from the numerical simulations are compared with experimental results available in literature. The comparison shows that the force values are highly influenced by constitutive models and the choice of parameters sets, whereas the chip morphologies are mainly influenced by the uncut chip thickness and constitutive models. This work justifies the need for an appropriate set of parameters and constitutive model that replicate the machining behavior of Ti6Al4V alloy for different cutting conditions.

Highlights

The titanium alloy, especially Ti6Al4V, is one of the most important and commonly used alloys for its attractive properties in aerospace, biomedical, submarine applications, etc. as it exhibits elevated strength, low density, good corrosion resistance, excellent high temperature properties [1,2]
With m1 from Hou et al [30]) for uncut chip thickness of 60 μm are analyzed and compared with the experimental reference. Further they are investigated with different parameters sets of parameters with the three other uncut chip thickness (40 μm, 100 μm and 280 μm) considered in this study
For uncut chip thickness h = 40 μm, 60 μm and 100 μm, the RMS values of cutting force from JC and Johnson–Cook Model by HOU (JC-Hou) models with set 1 and set 2 parameters are very close to the experimental values within the range of ±5% and feed forces are in the range of ±20%

Summary

Introduction

The titanium alloy, especially Ti6Al4V, is one of the most important and commonly used alloys for its attractive properties in aerospace, biomedical, submarine applications, etc. as it exhibits elevated strength, low density, good corrosion resistance, excellent high temperature properties [1,2]. The titanium alloy, especially Ti6Al4V, is one of the most important and commonly used alloys for its attractive properties in aerospace, biomedical, submarine applications, etc. As it exhibits elevated strength, low density, good corrosion resistance, excellent high temperature properties [1,2]. Ti6Al4V has proved to be complex due to its inherent properties such as, low thermal conductivity and high reactivity along with the diversity of physical phenomena involved, including large elasto-plastic deformation, complex contact/friction conditions, thermo-mechanical coupling and chip separation mechanisms [4,5,6]. Finite element modeling is the most significant and extensively used numerical technique that is employed to investigate thermomechanical phenomena and nonlinearities involved in the simulation of machining process [6,7,8]

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