Study on the effects of abrasive particle shape on the cutting performance of Ti-6Al-4V materials based on the SPH method

Lin, Feng; Liu, G. R.; Li, Zengliang; Dong, Xiangwei; Du, Mingchao

doi:10.1007/s00170-018-3119-y

Cited by 18 publications

(6 citation statements)

References 26 publications

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“…Also, Haghin et al [5] claimed that AWJ can machine a various range of ductile and brittle materials, and it has excellent characteristics such as high processing efficiency, no thermal effect, and environmental benign. Moreover, AWJ cutting is superior to many other cutting technologies in processing various materials, particularly in contouring or profile cutting and in processing difficult-to-cut materials such as titanium alloys [6]. However, the cutting performance of hard materials is still far from satisfactory, which greatly limits the application [7].…”

Section: Introductionmentioning

confidence: 99%

A new strategy for improving the surface quality of Ti6Al4V machined by abrasive water jet: reverse cutting with variable standoff distances

Xiong

Wan

Qian

et al. 2022

Int J Adv Manuf Technol

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Titanium alloys are widely used in important structures of aerospace vehicles, but the low thermal conductivity and high chemical activity make them difficult to process. As an untraditional machining technology, abrasive water jet (AWJ) has been proven to be an effective method for this kind of material. Aimed at further improving the cutting performance, reverse cutting with variable standoff distance (SOD) strategy was put forward, and experiments of titanium alloy Ti6Al4V machined by AWJ were conducted. The influence of SOD with different reverse cutting types on the kerf quality was studied to obtain the optimal SOD combinations. Ra, Sa and kerf taper were used to evaluate the quality of the machined surface. Moreover, the results of reverse cutting at the same speed and efficiency and single cutting at the constant SOD were compared and analyzed. It was found that the proposed strategy results in higher kerf quality in the aspect of surface roughness, compared to the single cutting. To be more specific, for the reverse trimming cutting, the improvements of Ra and Sa can reach up to 62.8% and 73.1% respectively under the condition of the SOD of the second cutting is 8mm. Furthermore, the kerf taper can be reduced 26.1% when the SOD of the second cutting is 2mm. With respect to the reverse deepening cutting, even the traverse speed of reverse cutting is set as twice as that of a single cutting, the kerf quality is still better. Additionally, when the SOD of the second cutting is 4mm, the improvements of Ra and Sa can reach up to 51.7% and 14.9%, respectively, and the kerf taper is reduced by 20.2%. This study provides a new method for improving the machined surface quality of hard materials, especially for Ti6Al4V.

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Section: Introductionmentioning

confidence: 99%

A new strategy for improving the surface quality of Ti6Al4V machined by abrasive water jet: reverse cutting with variable standoff distances

Xiong

Wan

Qian

et al. 2022

Int J Adv Manuf Technol

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“…The discretized conservation equations and constitutive equations are solved to obtain the time variation of the state variables. The method is described in detail in Liu and Liu [26], and also summarized in Feng et al [27].…”

Section: Smoothed Particle Hydrodynamics (Sph) Methodsmentioning

confidence: 99%

A Realistic Full-Scale 3D Modeling of Turning Using Coupled Smoothed Particle Hydrodynamics and Finite Element Method for Predicting Cutting Forces

Ojal

Copenhaver

Cherukuri

et al. 2022

JMMP

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Computational modelling is an effective technique for understanding the complex physics of machining. Large deformations, material separation, and high computational requirements are the key challenges faced while simulating machining. This work introduces a full-scale three-dimensional model of turning operations using a combined approach based on the Smoothed Particle Hydrodynamics (SPH) and Finite Element (FE) methods. By exploiting the advantages of each method, this approach leads to high-fidelity coupled SPH-FE machining models. Cutting forces and chip morphology are the primary results of interest. The machining models are validated with the results of turning experiments. Two-dimensional machining model underpredicts the cutting force and feed force by approximately 49% and 70%, respectively. Moreover, passive force cannot be predicted using the two-dimensional model. On the other hand, with the three-dimensional models developed in this manuscript, the difference between the total simulated force and experimentally measured force is ∼17%. The chip morphologies correlate with experiments in terms of the direction of the chip movement and the “long” continuous chips observed while turning Al 6061. This work expands the realm of machining simulations from two-dimensional orthogonal machining or sectional three-dimensional model to a full-scale realistic simulation. The encouraging simulation results show the potential to study more complex phenomena, such as machining stability and tool path modulation.

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“…This method can avoid the drawbacks of mesh‐based algorithms and has good adaptability to solve large deformation impacts. In modeling, Feng et al 9 visualized the abrasive particles in the jet by the SPH method, added the coupling relationship between abrasive particles and water and studied the interaction between water and abrasive particles in the process of abrasive water jet cutting. Dong et al 10 established a solid particle impact process model to study the removal form of ductile targets.…”

Section: Introductionmentioning

confidence: 99%

Study on abrasive particle impact modeling and cutting mechanism

Lin

Zhang

et al. 2021

Energy Science & Engineering

Self Cite

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Abrasive water jet impact is widely applied in processing, oil fracturing, coal mining, rock crushing, and other engineering fields. The influence of abrasive particles on cutting performance is one of the main characteristics of this technology, which is different from pure fluid cutting. Therefore, as for improving the cutting performance of abrasive water jet, studying the cutting mechanism of abrasive water jet, and clarifying the mapping relationship between particle parameters and cutting, it is of great theoretical and practical significance to clarify the impact failure mechanism and material removal mechanism of abrasive particles in the process of high‐speed impact. In order to study the effect of abrasive particles on cutting performance, irregular abrasive particles are simplified to angular particles and circular particles in this paper. The impact shooting process of particles in abrasive jet cutting is numerically simulated by using smoothed particle hydrodynamics (SPH) method, and the target impact experiments are carried out. The fracture processes of ductile materials and brittle targets impacted by different shapes of particles are studied. The results are showed as follows. Firstly, the SPH numerical model has high accuracy and successfully reproduces the collision process of particles in the process of abrasive jet cutting, including the deformation mechanisms such as plowing, cracking and crushing of the target, and the error of the dent curve formed by the collision is less than 0.5 mm. Secondly, the impact mechanism of angular and circular particles is different for targets with different material properties. For ductile materials, the process of material accumulating to failure value is slow, mainly by the way of accumulation removal. And for brittle materials, it mainly produces plastic deformation and failure, without obvious material accumulation and extrusion area. Thirdly, different impact angles of particles have great influence on material removal.

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Study on the effects of abrasive particle shape on the cutting performance of Ti-6Al-4V materials based on the SPH method

Cited by 18 publications

References 26 publications

A new strategy for improving the surface quality of Ti6Al4V machined by abrasive water jet: reverse cutting with variable standoff distances

A new strategy for improving the surface quality of Ti6Al4V machined by abrasive water jet: reverse cutting with variable standoff distances

A Realistic Full-Scale 3D Modeling of Turning Using Coupled Smoothed Particle Hydrodynamics and Finite Element Method for Predicting Cutting Forces

Study on abrasive particle impact modeling and cutting mechanism

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