Predicting the High Speed Cutting Process of Titanium Alloy by Finite Element Method
Predicting the High Speed Cutting Process of Titanium Alloy by Finite Element Method
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DOI：
10.1115/msec2011-50208
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发表时间：
2011
期刊：
影响因子：
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通讯作者：
X. Zhang;Xueping Zhang;A. Srivastava
中科院分区：
文献类型：
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作者：
X. Zhang;Xueping Zhang;A. Srivastava
为了准确预测高速干切削Ti-6Al-4V合金时的切削力和切削温度，基于ABAQUS建立了有限元模型。利用正交切削试验测得的切削力和切屑形态参数，解析计算了刀具-切屑-工件摩擦系数。结果表明，刀具-工件间的摩擦系数比刀具-切屑间的摩擦系数大3 ~ 7倍，且刀具-切屑-工件间的摩擦系数随进给量的变化而变化。该分析提供了一个更好的参考工具-工件-切屑摩擦系数比文献经验，无论加工条件。基于修正的Johnson-Cook模型和解析得到的刀具-工件-切屑摩擦系数，建立的有限元模型能够有效地模拟Ti-6Al-4V合金的高速干切削过程。有限元模型进一步验证预测力和芯片形态。有限元模型预测的切削力、推力和合力与实验测量的切削力吻合较好。切屑间距平均值和切屑峰谷距离的预测误差较小。有限元模型进一步预测了高速干切削Ti-6Al-4V合金时的切削温度和残余应力。最高刀具温度存在于沿着圆形刀具边缘，无论加工条件如何，沿加工表面的残余应力分布沿着呈钩形。Copyright © 2011 by ASME
To predict the cutting forces and cutting temperatures accurately in high speed dry cutting Ti-6Al-4V alloy, a Finite Element (FE) model is established based on ABAQUS. The tool-chip-work friction coefficients are calculated analytically using the measured cutting forces and chip morphology parameter obtained by conducting the orthogonal (2-D) machining tests. It reveals that the friction coefficients between tool-work are 3∼7 times larger than that between tool-chip, and the friction coefficients of tool-chip-work vary with feed rates. The analysis provides a better reference for the tool-work-chip friction coefficients than that given by literature empirically regardless of machining conditions. The FE model is capable of effectively simulating the high speed dry cutting process of Ti-6Al-4V alloy based on the modified Johnson-Cook model and tool-work-chip friction coefficients obtained analytically. The FE model is further validated in terms of predicted forces and the chip morphology. The predicted cutting force, thrust force and resultant force by the FE model agree well with the experimentally measured forces. The errors in terms of the predicted average value of chip pitch and the distance between chip valley and chip peak are smaller. The FE model further predicts the cutting temperature and residual stresses during high speed dry cutting of Ti-6Al-4V alloy. The maximum tool temperatures exist along the round tool edge, and the residual stress profiles along the machined surface are hook-shaped regardless of machining conditions.Copyright © 2011 by ASME