Finite element simulation of high-speed machining of titanium alloy (Ti–6Al–4V) based on ductile failure model

Chen, Guang; Ren, Chengzu; Yang, Xiaoyong; Jin, Xiaoning; Guo, Tao

doi:10.1007/s00170-011-3233-6

Cited by 232 publications

(93 citation statements)

References 24 publications

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“…It should be noted that principal characteristics of the shear band flow (shear band angle, spacing between bands) are not affected significantly by the use of different Johnson-Cook material parameters for Ti-6Al-4V [43] or different values of maximum shear stress in the friction model. However, the shear amplitude parallel to the band does vary to some extent.…”

Section: (A) Proceduresmentioning

confidence: 99%

“…These FE simulations of shear banding are carried out using the ABAQUS/EXPLICIT dynamics solver in a Lagrangian framework. While FE simulations of shear banding in machining are routine [43], as is the FE procedure used in the present work, interrogating the resulting strain-rate and velocity fields in particular ways can be very helpful in revealing features of shear band flow.…”

Section: Appendix a Finite-element Analysismentioning

confidence: 99%

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Geometric flow control of shear bands by suppression of viscous sliding

et al. 2016

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Shear banding is a plastic flow instability with highly undesirable consequences for metals processing. While band characteristics have been well studied, general methods to control shear bands are presently lacking. Here, we use high-speed imaging and micro-marker analysis of flow in cutting to reveal the common fundamental mechanism underlying shear banding in metals. The flow unfolds in two distinct phases: an initiation phase followed by a viscous sliding phase in which most of the straining occurs. We show that the second sliding phase is well described by a simple model of two identical fluids being sheared across their interface. The equivalent shear band viscosity computed by fitting the model to experimental displacement profiles is very close in value to typical liquid metal viscosities. The observation of similar displacement profiles across different metals shows that specific microstructure details do not affect the second phase. This also suggests that the principal role of the initiation phase is to generate a weak interface that is susceptible to localized deformation. Importantly, by constraining the sliding phase, we demonstrate a material-agnostic method—passive geometric flow control—that effects complete band suppression in systems which otherwise fail via shear banding.

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Section: (A) Proceduresmentioning

confidence: 99%

Section: Appendix a Finite-element Analysismentioning

confidence: 99%

Geometric flow control of shear bands by suppression of viscous sliding

et al. 2016

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“…Chen et al [14] analyzed with a FE code the distribution of stresses, temperature, and strains during the process of chip segmentation in orthogonal cutting. It was shown that thermal softening predominates over strain hardening along adiabatic shear band during segmented chip formation while strain hardening predominates over thermal softening between two adjacent shear bands Bäker et al [15] and Bäker [16], developed a two dimensional finite element model of orthogonal cutting process and analyzed the influence of material parameters on cutting forces and on the chip formation.…”

Section: Introductionmentioning

confidence: 99%

Analysis of adiabatic shear banding in orthogonal cutting of Ti alloy

Miguélez¹,

Soldani²,

Molinari³

2013

International Journal of Mechanical Sciences

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This work is focused on the numerical analysis of adiabatic shear banding in orthogonal cutting of Ti6Al4V alloy. Segmented chip results from adiabatic shear banding, depending on the competition of thermal softening and strain and strain rate hardening. The influence of cutting velocity and feed in the chip segmentation is studied. Also the role of friction at the tool-chip interface and the effect of rheological parameters of the constitutive equation are analyzed. Experimental tests obtained from previous work of the authors [Molinari A, Musquar C, Sutter G, Adiabatic shear banding in high speed machining of Ti-6Al-4V experiments and modeling, Int J Plast, vol. 18, 2002, p. 443-459] and others were used as a reference to validate the models. Cutting forces and the mechanism of plastic flow localization are analyzed in terms of frequency of segmentation and shear band width and compared to experimental data.

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“…Most of the constitutive laws reported can be attributed to the group of local models in which the total deformation gradient has been decomposed into elastic and plastic parts multiplicatively [39][40] . However, if the grain scale is too smaller, the local model will be insufficient owing to its inability to describe the size effects.…”

Section: Page 10 Of 16 Journal Of Materials Researchmentioning

confidence: 99%

Evolution of surface grain structure and mechanical properties in orthogonal cutting of titanium alloy

Bai

Tong

et al. 2016

J. Mater. Res.

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Abstract:In this study, a mesoscale dislocation simulation method was developed to study the orthogonal cutting of Titanium alloy. The evolution of the surface grain structure and its effects on the mechanical properties was studied using two-dimensional climb assisted dislocation dynamic technology. The motions of edge dislocations in an elastic matrix such as dislocation nucleation, lock, interaction with obstacles and grain boundaries, and annihilation were tracked. The results showed that the machined surface has a graded microstructure composed of ultrafine grains. A grain refinement process was observed in micro-cutting of titanium alloy. The process can be described as follows: (i) the development of dislocation lines in original grains, (ii) the formation of dense dislocation bands, (iii) the transformation of dislocation bands into subgrain boundaries, and (iv) the continuous dynamic recrystallization in subgrain boundaries. The fine-grains formed in this process bring appreciable scale effect and a mass of dislocations pile up in the grain boundary and persistent slip band (PSB). In particular, the flow stress and hardening rate was reduced by dislocation climb. However, this effect is significantly weakened when grain size was less than 1.65 µm. In addition, a Hall-Petch type relation is predicted depending on the amount of slips, the dislocation density, the grain arrangement and the range of grain sizes to which a Hall-Petch expression is fit. The numerical results obtained were compared with experimental data gathered from literature and a satisfied agreement was found.

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Finite element simulation of high-speed machining of titanium alloy (Ti–6Al–4V) based on ductile failure model

Cited by 232 publications

References 24 publications

Geometric flow control of shear bands by suppression of viscous sliding

Geometric flow control of shear bands by suppression of viscous sliding

Analysis of adiabatic shear banding in orthogonal cutting of Ti alloy

Evolution of surface grain structure and mechanical properties in orthogonal cutting of titanium alloy

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