Improved analytical prediction of chip formation in orthogonal cutting of titanium alloy Ti6Al4V

Bai, Wei; Sun, Ronglei; Roy, Anish

doi:10.1016/j.ijmecsci.2017.08.054

Cited by 68 publications

(59 citation statements)

References 46 publications

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“…Some of them analyzed chip geometry from an analytical point of view, resulting in the formulation of some theoretical models [26][27][28]. However, in these cases, many simplifications had to be made with regard to the complexity of the chip formation process and, hence, some of the real, practically obtained results have not correspond to the predictions of various parameters to set up a chip geometry, and the results were inaccurate [29][30][31]. Next, analyses of the chip formation used numerical models (finite element method, FEM) to simulate the chip generation process [32][33][34][35].…”

Section: State Of the Artmentioning

confidence: 99%

Comparative Study of Chip Formation in Orthogonal and Oblique Slow-Rate Machining of EN 16MnCr5 Steel

Monková

Monka

Sekerakova

et al. 2019

Metals

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In today's unmanned productions systems, it is very important that the manufacturing processes are carried out efficiently and smoothly. Therefore, controlling chip formation becomes an essential issue to be dealt with. It can be said that the material removal from a workpiece using machining is based on the degradation of material cohesion made in a controlled manner. The aim of the study was to understand the chip formation mechanisms that can, during uncontrolled processes, result in the formation and propagation of microcracks on the machined surface and, as such, cause failure of a component during its operation. This article addresses some aspects of chip formation in the orthogonal and oblique slow-rate machining of EN 16MnCr5 steel. In order to avoid chip root deformation and its thermal influence on sample acquisition, that could cause the changes in the microstructure of material, a new reliable method for sample acquisition has been developed in this research. The results of the experiments have been statistically processed. The obtained dependencies have uncovered how the cutting tool geometry and cutting conditions influence a chip shape, temperature in cutting area, or microhardness according to Vickers in the area of shear angle.

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Section: State Of the Artmentioning

confidence: 99%

Comparative Study of Chip Formation in Orthogonal and Oblique Slow-Rate Machining of EN 16MnCr5 Steel

Monková

Monka

Sekerakova

et al. 2019

Metals

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“…Therefore, low cutting speeds are usually used when turning [4][5][6]. Although the Ti6Al4V titanium alloy is a widely known material, it belongs to the difficult-to-cut materials group with a complicated process of chip formation [7][8][9].…”

Section: Introductionmentioning

confidence: 99%

“…The process of chip formation when titanium alloys turning attracts a lot of interest in the world of science, and difficulties in processing these materials caused that modeling and simulating studies are carried out [7,[10][11][12][13], as well as experimental researches. In machining processes, the shape and type of chips contain detailed information about the physical mechanisms, as well as the cutting process and workpiece features.…”

Section: Introductionmentioning

confidence: 99%

On the analysis of chip shaping after finishing turning of Ti6Al4V titanium alloy under dry, wet and MQL conditions

Leksycki

Feldshtein

2019

Archives of Mechanical Technology and Materials

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The shape and type of chip give general information about the cutting process. This paper presents the results of testing the shape and type of chips of Ti6Al4V titanium alloy after it finishes turning. The process was carried out under dry, wet and MQL (Minimum Quantity Lubrication) conditions at variable cutting speeds and feed rates and a constant depth of cutting. For planning the tests, the PSI (Parameter Space Investigation) method was used, which allows the experiment to be carried out while minimizing the number of experience points. It was found that the cutting speed and feed affect the type and shape of the chip, and clear differences were observed between dry and wet cooling conditions, and MQL conditions. During turning, the intensity of the cutting speed and feed influence on the chip compression ratio was changed. It was similar for dry and wet cooling conditions but smaller for MQL conditions. The purpose of this research is to analyze the chip shaping when Ti6Al4V titanium alloy finishes turning under dry, wet and MQL cooling conditions.

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“…Eng. (2018) 31:103 analytical model of milling force is established by the flow stress, constitutive equation of material and geometric relations of milling, which is the combination of theory such as thermo-elastic-plastic, tribology, materials science and dynamics [5][6][7][8].…”

Section: Introductionmentioning

confidence: 99%

“…Oxley [5] modified the single shear area to a shear zone and established the parallel-sided shear zone model. Astakhov et al [10], Bai et al [7], Zhou et al [11] divided the shear zone into two regions, i.e., wide zone and narrow zone, and predicted the cutting force by analyzing the flow rules and thermodynamics equations of material in the shear zone.…”

Section: Introductionmentioning

confidence: 99%

A Model for Predicting Dynamic Cutting Forces in Sand Mould Milling with Orthogonal Cutting

Shan

Fang

2018

Chin. J. Mech. Eng.

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Cutting force is one of the research hotspots in direct sand mould milling because the cutting force directly affects the machining quality and tool wear. Unlike metals, sand mould is a heterogeneous discrete deposition material. There is still a lack of theoretical research on the cutting force. In order to realize the prediction and control of the cutting force in the sand mould milling process, an analytical model of cutting force is proposed based on the unequal division shear zone model of orthogonal cutting. The deformation velocity relations of the chip within the orthogonal cutting shear zone are analyzed first. According to the flow behavior of granular, the unequal division shear zone model of sand mould is presented, in which the governing equations of shear strain rate, strain and velocity are established. The constitutive relationship of quasi-solid-liquid transition is introduced to build the 2D constitutive equation and deduce the cutting stress in the mould shear zone. According to the cutting geometric relations of up milling with straight cutting edge and the transformation relationship between cutting stress and cutting force, the dynamic cutting forces are predicted for different milling conditions. Compared with the experimental results, the predicted results show good agreement, indicating that the predictive model of cutting force in milling sand mould is validated. Therefore, the proposed model can provide the theoretical guidance for cutting force control in high efficiency milling sand mould. which permits unrestricted use, distribution, and reproduction in any medium, provided you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made.the ability of the process, surface quality, and monitoring the tool wear [2]. Milling is one of the most complex machining processes. At present, the models for predicting cutting forces mainly include empirical model, numerical model, artificial intelligence model and analytical model. The empirical model is expressed as an exponential function of cutting force and process parameters, based on the statistical and regression analysis of orthogonal experimental results [3]. FEM is the common numerical method for building the model, which can be used to analyze the chip deformation, tool wear, stress and temperature distribution, and optimize the process parameters. Through artificial neural network (ANN) [4] and particle swarm optimization (PSO) and other modern artificial intelligence algorithms, more accurate milling force model is established. The

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Improved analytical prediction of chip formation in orthogonal cutting of titanium alloy Ti6Al4V

Cited by 68 publications

References 46 publications

Comparative Study of Chip Formation in Orthogonal and Oblique Slow-Rate Machining of EN 16MnCr5 Steel

Comparative Study of Chip Formation in Orthogonal and Oblique Slow-Rate Machining of EN 16MnCr5 Steel

On the analysis of chip shaping after finishing turning of Ti6Al4V titanium alloy under dry, wet and MQL conditions

A Model for Predicting Dynamic Cutting Forces in Sand Mould Milling with Orthogonal Cutting

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