In this paper, ABAQUS finite element simulation software was used to establish a more reliable three-dimensional milling titanium alloy Ti6Al4V finite element simulation model. This model sets up important links such as the material constitutive model, the tool-chip contact friction model, and the chip separation criterion. And the accuracy of the model is verified by experiments. Based on this model, orthogonal experiment was used to explore the effects of axial cutting depth, tool speed and feed speed on the milling force. And the morphology of the chip and the surface morphology of the machined workpiece were investigated. The results show that the influence of cutting parameters on milling force from high to low is as follows: axial cutting depth > tool speed > feed rate. The change of cutting parameters has different influence on milling force in all directions, and has the largest influence on milling force in X direction.
The main purpose of this paper was to investigate the effect of the multiple ultrasonic surface rolling process (USRP) on the surface mechanical properties and wear mechanism of Ti-6Al-4V. Firstly, X-ray diffraction (XRD) microscopic analysis, work hardening and residual stress were used to measure and characterize the surface performance by USRP. The friction coefficient and wear morphology were obtained by the scanning electron microscope (SEM), three-dimension (3D) white light interferometer and energy dispersive spectrometer (EDS). The results showed that the material surface mechanical properties was effectively improved by the USRP, and the surface grains were refined to form nanoscale. It also can be found that the wear resistance of the material surface was effected by the surface mechanical properties. With the increase of processing, the main wear mechanism changed from delamination-based oxidation wear to adhesive wear with the increase of processing.
Accurate measurement of cutting force is an important means to study metal cutting process. In this paper, the measurement of drilling force for stainless steel is studied by means of drilling experiments. It is found that the measured values of drilling force are dispersive under the same conditions. The uniformity of mechanical properties of workpiece materials has a great influence on the value of drilling force. In calculating cutting force by finite element method, it is necessary to ensure that the performance parameters of the input material are consistent with the actual performance parameters of the workpiece.
Ti6Al4V is a difficult to machine alloy with low cutting efficiency and server tool wear. A series of orthogonal turning tests with coated carbide in higher speed scale was carried out on a CA6140 lathe. The experiential functions of tool life based on orthogonal experiment were developed. The tool wear morphologies were examined by scanning electron microscope (SEM) and energy disperse spectroscopy (EDS), adhesion, diffusion and micro-chipping were the major wear mechanisms of coated carbide tool. Finally, the cutting parameters of coated carbide tool in Ti6Al4V dry turning were optimized based on tool life-efficiency contour analysis, in same cutting efficiency, the lower cutting speed and larger depth of cut are the better selection in Ti6Al4V turning for coated carbide tool.
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