Abstract
Ti6Al4V alloy is a well-known difficult-to-cut material used in different industrial applications, to achieve the expected component quality, proper definition and control of the machining process parameters must be accomplished. To address this problem, simulations with finite element method (FEM) seem to be an interesting engineering tool to model and optimize machining processes. Nevertheless, the model capability in capturing the behaviour observed in real machining processes is associated with the definition of the model and parameters that describe the workpiece flow stress. This contribution aimed to study the performance of built-in AdvantEdge-2D™ material laws applied in Ti6Al4V orthogonal cutting simulations under dry conditions. The numerical models were created under three levels of cutting speed, a constant feed rate and depth-of-cut, a variable tool rake angle (of 20° and −6°/0°), but also using four Ti6Al4V constitutive laws, namely, one suggested in AdvantEdge™ library, a Johnson-Cook (JC) model, a Power law (PL) and a PL coupled with ductile damage model. Experimental results were used to assess the numerical models’ accuracy in predicting the machining forces and metal chips. Satisfactory results regarding the machining forces prediction were achieved with all material laws, yet when the damage criterion was coupled with the constitutive laws (PLD and AE standard material law), the simulations were also were able to achieve the expected chip morphology (serrated metal chips).
Highlights
Ti6Al4V alloy is often selected for high-value applications in the aerospace, automotive, and biomedical manufacturing sectors, due to its excellent combination of properties including high strength-to-weight ratio, corrosion resistance and biocompatibility [1]
The standard model and the power-law model with damage were able to capture the serrated metal chips that are formed when machining Ti6Al4V alloy. This effect was not detected in the simulations conducted with the Johnson-Cook material model and the power law model
4 Conclusion: In this work it was investigated the effect of the workpiece material model and parameters, the standard model provided by the simulation software, the Johnson-Cook material model, the powerlaw model and the power law model with damage, in the thermo-mechanical response obtained during Ti6Al4V machining simulations using cutting tools with distinctive rake angles, namely, a tool with a positive rake angle and a tool with a double rake angle
Summary
Ti6Al4V alloy is often selected for high-value applications in the aerospace, automotive, and biomedical manufacturing sectors, due to its excellent combination of properties including high strength-to-weight ratio, corrosion resistance and biocompatibility [1]. One way to outcome this constraint is to create an AE custom material (as an alternative to standard) using the AE built-in model for the power law with damage (PLD) and manually define the parameters This approach was reported by Jiang et al [23] to simulate the metal chips formed in OC operations with AISI D2 alloy. Similar modelling strategy was applied by Ortiz-de-Zarate et al [29] in 2018, the authors conducted numericalexperimental work to study the thickness of the deformed layer and the maximum residual compression stress in machined surfaces They used models were created in DEFORM-2DTM using a JC law coupled with CL failure criterion. The minimum and maximum element size for the workpiece and tool were the same 0.02 of 0.2 mm, respectively
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