A new material model for 2D numerical simulation of serrated chip formation when machining titanium alloy Ti–6Al–4V

By M. Calamaz, D. Coupard, F. Girot. 2008

691 citations recorded by the source corpus.

Abstract A new material constitutive law is implemented in a 2D finite element model to analyse the chip formation and shear localisation when machining titanium alloys. The numerical simulations use a commercial finite element software (FORGE 2005®) able to solve complex thermo-mechanical problems. One of the main machining characteristics of titanium alloys is to produce segmented chips for a wide range of cutting speeds and feeds. The present study assumes that the chip segmentation is only induced by adiabatic shear banding, without material failure in the primary shear zone. The new developed model takes into account the influence of strain, strain rate and temperature on the flow stress and also introduces a strain softening effect. The tool chip friction is managed by a combined Coulomb–Tresca friction law. The influence of two different strain softening levels and machining parameters on the cutting forces and chip morphology has been studied. Chip morphology, cutting and feed forces predicted by numerical simulations are compared with experimental results.

Subfields: Biomedical Engineering, Civil and Structural Engineering, Mechanical Engineering

View Paper: https://www.semanticscholar.org/paper/852d1720249934216deee3e924aa4a69b443fccf

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Citations in the corpus

Temperature dependent flow softening of titanium alloy Ti6Al4V: An investigation using finite element simulation of machining (2011, methodology): “Calamaz et al. (2008) summarized various possible echanisms that would lead to flow softening, such as the platelet inking suggested by Miller et al. (1999). They also proposed a softning function integrated to the Johnson and Cook (1983) material odel. The proposed material model assumes that flow ”
Machining of Titanium Alloy (Ti-6Al-4V)—Theory to Application (2015, methodology): “The temperature generation the chip during formation is given in Figure 5 (Calamaz et al., 2008).”
On the importance of the choice of the parameters of the Johnson-Cook constitutive model and their influence on the results of a Ti6Al4V orthogonal cutting model (2017, background): “[12] consider that the Johnson-Cook flow stress should not be adopted for strains larger than 0.”
On the selection of Johnson-Cook constitutive model parameters for Ti-6Al-4V using three types of numerical models of orthogonal cutting (2015, methodology): “Cutting parameters and tool geometry [18, 35].”