Abstract
This work establishes a 2D numerical model to simulate the cutting process of workpieces made of Ti–6Al–4V, by applying an improved Smoothed Particle Hydrodynamics algorithm together with a modified constitutive model based on the Johnson–Cook model known as Hyperbolic Tangent (TANH). The location information of the surface particles obtained by the SPH cutting model are used to evaluate the variation trend of surface roughness with different parameters. Parameters that affect the surface roughness are investigated in detail by using the Taguchi method and the SPH cutting model. The present work provides an efficient and cost-effective approach to determine the optimal parameters for cutting processes for Ti–6AL–4V workpieces, through computer simulations in virtual environments, instead of expensive and time-consuming cutting experiments using actual workpieces.
Highlights
Ti–6AL–4V is one of most popular titanium alloys in many engineering applications
This paper proposes an approach to investigate the effects of cutting parameters on surface roughness by combining the numerical simulation of the cutting process and the Taguchi method
We employed the Taguchi method to investigate the effects of cutting parameters on the variance trend of surface roughness
Summary
Ti–6AL–4V is one of most popular titanium alloys in many engineering applications. It is an important material for modern mechanical components and equipment, especially in biomedical and aerospace systems, since it has superb corrosion resistance, and has a high strength to weight ratio. This paper proposes an approach to investigate the effects of cutting parameters on surface roughness by combining the numerical simulation of the cutting process and the Taguchi method. We employ the Taguchi method which involves establishing an orthogonal simulation array, applying an S/N ratio and ANOVA to investigate the effects of cutting parameters on surface roughness. (2) proposes a Surface Particles Method (SPM) to evaluate the variation trend of surface roughness with different parameters instead of the real experiments for cutting Ti–6AL–4V and substantially reduces work time and cost; (3) investigates the influence of cutting parameters on surface roughness during cutting by the Taguchi method and avoids the laborious experimental process; and 4) compares our simulation results with experimental results to testify the effectiveness. The comparison shows that our method is reliable and effective to investigate the effects of cutting parameters on surface roughness
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