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

Abstract

Current constraints on aeronautical parts have led to the introduction of materials like titanium alloys as well as new part geometries featuring large dimensions and reduced thickness. Inappropriate cutting forces during turning operations could lead to high deflections and damage to the machine. In order to ensure the respect of final part geometry and the optimal use of resources, cutting forces have to be known, to anticipate the deformed shape during and after machining operations on thin parts. Current models are offering a solution which can be optimised by the modelling influence of the ploughing effect on cutting forces. Therefore, a mechanistic model is developed in order to improve the prediction of cutting forces during turning operations on titanium alloy Ti6Al4V: this model includes the effect of the clearance face contact radius and comprises two main steps. First, the effect of the clearance contact radius and the effect of the cutting edge lead angle are determined independently, via a direct identification method based on elementary cutting tests. Secondly, this analysis is extended to cutting trials in boring, cylindrical turning and face turning. Then, based on a mechanistic approach, a model is defined according to the previous results and the coefficients are identified thanks to cutting trials in real conditions. The results of the proposed model are then compared to a commonly used model which takes into account mostly the uncut chip thickness effect. It is demonstrated that the proposed cutting force model provides a more accurate prediction of cutting forces.

Machining of titanium alloys for medical application - a review

“…Also, it was concluded that the optimal cutting parameters for turning titanium alloys are 75 m/ min for V c , 0.25 mm/rev for f, 0.25 mm for a p , and 23°f or rake angle. Dorlin et al 42 compared with experimental tests a proposed model of cutting force and concluded that cutting forces increased with contact radius increase. C xelik et al 43 investigated the effect on tool wear and surface quality in dry turning with CVD and PVD coated tools and concluded that not only there is a general increase in wear in both types of tools when cutting parameters become more demanding, but this also led to worse surface quality.…”

Study on Magnetization Treatment and Cutting Performance of a New-Type of Triethanolamine Borate Cutting Fluid

“…Its diameter, shank diameter, edge length and overall length are 10 mm, 10 mm, 25 mm and 75 mm respectively. The workpiece used in the test was a TC4 titanium alloy with a density of with density of 4.51 g/cm 3 and the hardness is HRC31. The additive used in the experiment is triethanolamine borate, defoamer is modified polyether and bactericide is isothiazolinone.…”

“…Titanium alloy has the advantages of high strength and good corrosion resistance and are widely used in aviation industry [1], [2], [3], [4]. However, titanium alloys also have the disadvantages of poor thermal conductivity, low elastic modulus and high chemical activity [5], [6], [7], which makes the processing of titanium alloy very difficult and has always been a problem in the field of aviation manufacturing [8].…”

Benchmarking of several material constitutive models for tribology, wear, and other mechanical deformation simulations of Ti6Al4V

“…It is obvious that the forces are much higher in the case of AdvantEdge. A summary of these results is presented in Table 12 showing In preparation of Figure 18 the works reviewed were that of (Dorlin, Fromentin et al 2016), (Bahi, List et al 2016), (Bai, Sun et al 2017), (Li, Qiu et al 2016), (Ruibin and Wu 2016), (Shalaby and Veldhuis 2018) and (Vosough, Schultheiss et al 2013). There are a number of other works reported on machining Ti6Al4V but we draw this brief comparison merely for the purpose of comparing the results we obtained from our models rather than consolidating the entire series of experimental trials performed on Ti6Al4V to date.…”