3D FEM simulation of helical milling hole process for titanium alloy Ti-6Al-4V
3D FEM simulation of helical milling hole process for titanium alloy Ti-6Al-4V
复制标题
钛合金Ti-6Al-4V螺旋铣孔加工3D有限元模拟
DOI：
10.1007/s00170-015-7323-8
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发表时间：
2015-12-01
影响因子：
3.4
通讯作者：
Jin, Yan
中科院分区：
文献类型：
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作者：
Ji, Chunhui;Li, Yonghang;Jin, Yan
螺旋铣削加工作为一种新兴的孔加工方法，在航空材料制造领域，特别是在飞机结构件、模具、模具制造等领域的应用日益广泛。螺旋铣削加工由于其复杂的刀具几何形状和工件上的渐进材料失效而要求很高。利用商用有限元软件ABAQUS/EXPLICIT建立了钛合金Ti-6Al-4V螺旋孔的三维有限元模型。该模型考虑了工件材料中的损伤萌生和演化，模拟了螺旋孔的加工过程。建立了立铣刀钻头与工件接触面的接触模型，确定了工艺参数。此外，还提出了一种模拟程序，用于模拟具有相同失效参数的不同切削过程。利用该有限元模型，对加工钛合金进行了一系列有限元分析，并与实验室实验数据进行了对比。阐述了加工参数对螺旋铣削加工的影响，充分展示了有限元模拟螺旋铣削加工过程的能力和优势。
As an emerging hole-machining methodology, helical milling process has become increasingly popular in aeromaterials manufacturing research, especially in areas of aircraft structural parts, dies, and molds manufacturing. Helical milling process is highly demanding due to its complex tool geometry and the progressive material failure on the workpiece. This paper outlines the development of a 3D finite element model for helical milling hole of titanium alloy Ti-6Al-4V using commercial FE code ABAQUS/Explicit. The proposed model simulates the helical milling hole process by taking into account the damage initiation and evolution in the workpiece material. A contact model at the interface between end-mill bit and workpiece has been established and the process parameters specified. Furthermore, a simulation procedure is proposed to simulate different cutting processes with the same failure parameters. With this finite element model, a series of FEAs for machined titanium alloy have been carried out and results compared with laboratory experimental data. The effects of machining parameters on helical milling have been elucidated, and the capability and advantage of FE simulation on helical milling process have been well presented.