Abstract
Titanium alloy Ti6Al4V has the advantages of high specific strength, good heat resistance, and strong corrosion resistance, which is widely used in the manufacturing of aerospace industrial parts. However, in the side milling of titanium alloy, the temperature of the cutting area is high, and the cutting edge position is prone to breakage, which affects the surface quality of the workpiece. In order to reveal the tool damage failure mechanism in the milling process of titanium alloy, firstly, the impact force model when the tool cuts into the workpiece from the empty stroke and the milling force model during milling are established to obtain the cyclic load characteristics and impact effect of the tool. Then, based on the fatigue crack propagation theory and the energy balance equation of sliding crack, the elastic modulus and crack propagation law of tool material under different cutting impacts are analyzed. The interval method is used to recalculate the initial and critical damage value of tool material fracture in the maximum range. Finally, the limit conditions of the edge impact fracture of the end mill are established, and the safe cutting area of tool breakage is redefined. Through the milling test of titanium alloy, the impact damage morphology of tool in different states is redefined. The obtained redefined tool safety area provides a theoretical basis for high-speed and high-efficiency milling of titanium alloy, tool breakage, and tool life.
Highlights
At present, material failure is mainly to calculate damage by introducing microscopic defects
From the analysis of the domestic and foreign scholars study, tool damage characteristics of the research are mainly concentrated in the following aspects: tool breakage is based on the tool crack exists inside, and micro factors will extend with the milling, the impact caused by intermittent cutting and cyclic stress in the process of cutting will have an effect on tool failure, and the optimization of improving the cutting performance including the tool structure, cutting parameters
Based on continuous damage mechanics, fatigue crack growth theory and sliding crack energy balance equation, the crack growth law of tool material is studied under different cutting impact, and the initial and critical damage value of tool material fracture based on the interval method are obtained. the impact fracture limit conditions of the end mill edge are established, and the tool safety area range is obtained, which provide parameter optimization milling titanium alloy process
Summary
Material failure is mainly to calculate damage by introducing microscopic defects. It is urgent to study the properties of cemented carbide material and simulate the actual cyclic loading and material damage of cemented carbide tools in high speed milling of titanium alloy, so as to provide theoretical support for the failure mechanism of cemented carbide tool and impact fracture limit conditions. From the analysis of the domestic and foreign scholars study, tool damage characteristics of the research are mainly concentrated in the following aspects: tool breakage is based on the tool crack exists inside, and micro factors will extend with the milling, the impact caused by intermittent cutting and cyclic stress in the process of cutting will have an effect on tool failure, and the optimization of improving the cutting performance including the tool structure, cutting parameters. Based on continuous damage mechanics, fatigue crack growth theory and sliding crack energy balance equation, the crack growth law of tool material is studied under different cutting impact, and the initial and critical damage value of tool material fracture based on the interval method are obtained. the impact fracture limit conditions of the end mill edge are established, and the tool safety area range is obtained, which provide parameter optimization milling titanium alloy process
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