Analysis and Modelling of the Contact Radius Effect on the Cutting Forces in Cylindrical and Face Turning of Ti6Al4V Titanium Alloy

Abstract

Cutting forces are representative data to characterize machining operations.They have to be known to perform the part manufacturing. Therefore, cutting forces predictive models are useful and it is possible to optimize them by taking into account new parameters. Hence, this study deals with the geometrical modelling of tool-workpiece interaction and its influence on the cutting forces. The analysis focuses on convex contact radius between the machined part and the tool. Experiments are based on cylindrical and face turning of Ti6Al4V titanium alloy. The results highlight a significant influence of contact conditions on ploughing mechanisms, and consequently on the cutting forces intensity. This phenomenon is taken into account inthe suggested models, providing a better accuracy of cutting forces modelled.International audienceCutting forces are representative data to characterize machining operations.They have to be known to perform the part manufacturing. Therefore, cutting forces predictive models are useful and it is possible to optimize them by taking into account new parameters. Hence, this study deals with the geometrical modelling of tool-workpiece interaction and its influence on the cutting forces. The analysis focuses on convex contact radius between the machined part and the tool. Experiments are based on cylindrical and face turning of Ti6Al4V titanium alloy. The results highlight a significant influence of contact conditions on ploughing mechanisms, and consequently on the cutting forces intensity. This phenomenon is taken into account inthe suggested models, providing a better accuracy of cutting forces modelled

Generalised cutting force model including contact radius effect for turning operations on Ti6Al4V titanium alloy

“…Campocasso et al [26] support this assessment by highlighting the influence of the part radius on cutting forces in the cylindrical turning of pure copper Cu-OFE with an unworn round insert. This influence is also observed by Dorlin et al [27], in the case of Ti6Al4V titanium alloy turning with a worn round insert, who compared the cutting forces gathered from cylindrical turning and face turning tests. Considering that the contact conditions between the machined part and the cutting tool may have a significant influence on cutting forces, the effect of this influence has to be determined and included in future modelling.…”

“…As indicated by many researchers during finish turning operations using the tool nose, modelled with a round insert, many parameters are not constant along the cutting edge. This is the case of the uncut chip thickness [15,33], the cutting edge lead angle κ r and the clearance face contact radius as proposed by Campocasso et al [26] and illustrated by Dorlin et al [27] in Fig. 2 for cylindrical turning and face turning.…”

Modeling of cutting performances in turning process using artificial neural networks

“…They have to be known precisely in order to predict deflections on the machined part and optimize the industrialization of this part on the machines. 4 In order to have true values of cutting forces, they have to be measured during cutting process which leads to costly trials. Consequently, there is a necessity to develop reliable models that predict these forces and investigate the effects of turning parameters on them.…”

Prediction of 3D chip formation in the facing cutting with lathe machine using FEM

“…Most of published studies concerning on cylindrical turning despite there are some the other process cutting on a lathe i.e facing, threading, grooving, cutting off. Research on facing cutting (face turning) in experimental has done with by some researchers to investigate the performance of lathe machining process [1][2][3][4][5]. It starts from mild and alloyed steel material [1] then growing very fast on machining metal alloys [2] and most recently using of manufacture part material such Metal Matrix Composites [3][4] and Powder Metallurgy steels [5] The Johnson-Cook plasticity model is used to simulate the cutting process in lathe machining.…”

“…Many researchers have been simulated Orthogonal cutting with the use FEM simulation by using the Johnson-Cook plasticity model. Most of them were investigated tool wear, cutting force, temperature, heat transfer, deformation tool or workpiece material, chatter vibration during cutting process in lathe machining [1][2][3][4][5][6][7][8]. The HSS tool material was simulated where the model used in [6] for analysis bending occurring on material C1060 cutting process under constant conditions.…”