Abstract
A finite element modelling was carried out to analyse the chip morphology and adiabatic shear banding localisation processes when high-speed machining refractory titanium alloys. A thermo-visco-plastic model for the machined material and a rigid with thermal behaviour for the cutting tool were assumed. The study tries to understand the effect of the material behaviour on the produced chip morphology. One of the main characteristics of titanium chips is a segmented shape for a wide range of cutting conditions. This kind of morphology was found only dependent on adiabatic shear banding without material damage effect in the shear zones (primary and secondary shear zones). The influence of the material characteristics (strain softening, thermal softening, etc.) and machining parameters on the cutting forces and chip morphology were analysed. Three flow-stress laws and different friction coefficients (low and high friction) at the tool-chip interface was particularly analysed to explain the different morphologies obtained for refractory titanium chips.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Zhen-Bin H, Komanduri R (1995) On a thermo-mechanical model of shear instability in machining. Ann CIRP 44(1):69–73
Shaw MC, Dirke SO, Smith PA, Cook NH, Loewen EG, Yang CT (1954) Machining titanium, Massachusetts Institute of Technology, Cambridge, MA, USA
Komanduri R, Turkovich BF (1981) New observations on the mechanism of chip formation when machining titanium alloys. Wear 69:179–188
Vyas A, Shaw MC (1999) Mechanics of saw-tooth chip formation in metal cutting. J Manufact Sci Eng 121:165
Hua J, Shivpuri R (2004) Prediction of chip morphology and segmentation during the machining of titanium alloys. J Mater Process Technol 150:124–133
Bayoumi AE, Xie JQ (1995) Some metallurgical aspects of chip formation in cutting Ti-6 wt.% Al-4 wt.%V alloy. Mater Sci Eng Abstr 190:173–180
Baker M, Rösler J, Siemers C (2002) A finite element model of high speed metal cutting with adiabatic shearing. Comput Struct 80(5–6):495–513
Li L, He N (2006) A FEA study on mechanisms of saw-tooth chip deformation in high speed cutting of Ti-6-Al-4 V alloy. In: Proceedings of the Fifth International conference on High Sped Machining, Metz, France. pp 759–767
Arrazola PJ, Ugarte D, Villar JA, Marya S (2006) Finite element modelling: a qualitative tool to study high speed machining. In: Proceedings of the Fifth International conference on High Sped Machining, Metz, France
Barge M, Hamdi H, Rech J, Bergheau J-M (2005) Numerical modelling of orthogonal cutting: influence of numerical parameters. J Mater Process Technol 164:1148–1153
Pantalé O, Bacaria J-L, Dalverny O, Rokotomalala R, Caperaa S (2004) 2D and 3D numerical models of metal cutting with damage effects. Comput Meth Appl Mech Eng 193:4383–4399
Guo YB, Yen DW (2004) A FEM study on mechanisms of discontinuous chip formation in hard machining. J Mater Process Technol 155–156:1350–1356
Ceretti E, Lucchi T, Altan T (1999) FEM simulation of orthogonal cutting: serrated chip formation. J Mater Process Technol 95:17–26
Obikawa T, Usui E (1996) Computational machining of titanium alloy-finite element modelling and a few results. Trans Am Soc Mech Eng 118:208–215
Guo YB, Wen Q, Woodbury KA (2006) Dynamic material behavior modelling using internal state variable plasticity and its application in hard machining simulations. J Manuf Sci Eng 128:749–756
Rhim S-H, Oh S-I (2006) Prediction of serrated chip formation in metal cutting process with new flow stress model for AISI 1045 steel. J Mater Process Technol 171:417–422
Kassner ME, Wang MZ, Perez-Prado M-T, Alhajeri S (2002) Large-strain softening of aluminium in shear at elevated temperature. Metall Mater Trans A 33A:3145–3153
Pettersen T, Nes E (2003) On the origin of strain softening during deformation of aluminium in torsion to large strains. Metall Mater Trans A 34A:2727–2736
Ding R, Guo ZX (2004) Miscrostructural evolution of a Ti-6Al-4V alloy during β-phase processing: experimental and simulative investigations. Mater Sci Eng A365:172–179
Baker M (2006) Finite element simulation of high-speed cutting forces. J Mater ProcessTechnol 176:117–126
Gruau C, Coupez T (2003) Anisotropic and multidomain mesh automatic generation for viscous flow finite element method. In: Proceedings of the International conference on Adaptative and Modeling Simulation (ADMOS 03), Goteburg, Sweden
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
About this article
Cite this article
Calamaz, M., Coupard, D., Nouari, M. et al. Numerical analysis of chip formation and shear localisation processes in machining the Ti-6Al-4V titanium alloy. Int J Adv Manuf Technol 52, 887–895 (2011). https://doi.org/10.1007/s00170-010-2789-x
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-010-2789-x