Investigation of friction modeling on numerical Ti6Al4V cutting simulations

Abstract

Friction significantly influences chip formation, thereby highlighting its modeling critical in numerical cutting simulations. Notably, issues like the underestimation of feed force in simulations are often attributed to inadequate friction models. Nevertheless, diverse conclusions in the literature regarding friction’s behavior complicate the accurate implementation of this input. Additionally, the enormous of the available friction models and their varied calibration methods introduce further debates over which aspects of friction modeling should receive more focus. These controversies and deficiencies hinder progress in further understanding friction’s role in chip formation through numerical studies. Instead of proposing or calibrating new friction models, the current study, based on Ti6Al4V machining simulations, attempts to readdress the aforementioned controversies in a neutral stance by conducting sensitivity studies using a hybrid Smoothed Particle Hydrodynamics (SPH) - Finite Element Method (FEM) solver with Graphics Processing Units (GPU) acceleration, which is capable of efficiently executing high-resolution computations. The significant impact of friction particularly at the end of the tool-chip contact on the chip formation, physical contact states and process forces are highlighted. The behaviors of physical parameters including normal contact pressure, sliding velocity, and temperature-dependent friction models in the literature are also evaluated. Several aspects such as the shear flow stress limit, the relationship between friction and process forces, and the selection of different models are discussed. In conclusion, pragmatic recommendations for friction modeling and cutting simulation work are provided. On the one hand, the available complex physical parameter dependent friction models could not prove their necessity and should be approached cautiously. Instead, the constant Coulomb friction model without the shear stress limit, despite its simplicity, demonstrates effective and sufficient for a single set of metal cutting simulations. On the other hand, reliable on-site measurement techniques of the coefficient of friction (COF) at the tool-chip sliding contact area should be developed, with consideration of the contact length and the state of material flow. Combined with careful cutting edge preparation and suitable constitutive models, the overall accuracy of numerical cutting simulations including the feed force prediction are expected to be improved.