Material model assessment in Ti6Al4V machining simulations with FEM

Abstract

Ti6Al4V alloy is a well-known difficult-to-cut material used in different industrial applications, to achieve the expected component quality, proper definition and control of the machining process parameters must be accomplished. To address this problem, simulations with finite element method (FEM) seem to be an interesting engineering tool to model and optimize machining processes. Nevertheless, the model capability in capturing the behaviour observed in real machining processes is associated with the definition of the model and parameters that describe the workpiece flow stress. This contribution aimed to study the performance of built-in AdvantEdge-2D™ material laws applied in Ti6Al4V orthogonal cutting simulations under dry conditions. The numerical models were created under three levels of cutting speed, a constant feed rate and depth-of-cut, a variable tool rake angle (of 20° and −6°/0°), but also using four Ti6Al4V constitutive laws, namely, one suggested in AdvantEdge™ library, a Johnson-Cook (JC) model, a Power law (PL) and a PL coupled with ductile damage model. Experimental results were used to assess the numerical models’ accuracy in predicting the machining forces and metal chips. Satisfactory results regarding the machining forces prediction were achieved with all material laws, yet when the damage criterion was coupled with the constitutive laws (PLD and AE standard material law), the simulations were also were able to achieve the expected chip morphology (serrated metal chips).

Numerical Modeling of Cutting Characteristics during Short Hole Drilling: Part 2—Modeling of Thermal Characteristics

“…This paper shows the advantageous effect of thermal properties on the temperature in different cutting zones [72][73][74][75]. In the development of numerical cutting models, thermal properties have mostly been chosen to be constant, as found in the data bank of material properties embedded in the commercial software tool used (see, e.g., [76][77][78]). If the thermal properties of the machined material were still determined, they were determined experimentally in most cases (see, e.g., [79,80]) and less often by theoretical [81] or analytical methods [82,83] using the generally accepted methods for investigating the properties of various materials (see, e.g., [79,84,85]).…”

Simulasi Gaya Pemotongan pada Proses Bubut dengan Software Third Wave Advantedge

“…Untuk menyederhanakan model, benda kerja dimodelkan sebagai sebuah bidang datar. Hal serupa dilakukan oleh beberpa peneliti sebelumnya [10,11]. Setelah dilakukan pemodelan, dilanjutkan dengan tahap memilih material pahat dan benda kerja.…”