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Numerical analysis of chip formation mechanisms in orthogonal cutting of Ti6Al4V alloy based on a CEL model

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Abstract

This article proposes an improved numerical model based on the coupled Eulerian-Lagrangian (CEL) formulation for the numerical analysis of metal cutting. Preliminary calculation results show that the model overcomes some shortcomings of traditional finite element (FE) models, for example, the mesh distortion and the limitation of the separation line method in the Lagrangian approach and setting the chip shape in advance in the Eulerian approach. Therefore, application of this model can provide a convenient simulation for stable and unstable cutting processes of metals and a vivid demonstration for the streamline field of plastic flow of a workpiece material during cutting. Moreover, it can accurately characterize the evolutions of stress, strain, and temperature fields in the chip, the variation histories of the cutting force with time and the shear-localized instability behaviors in the serrated chip. The simulation results have sufficiently demonstrated the potential of applying the CEL model to the numerical analysis of metal cutting. In particular, the CEL model facilitates the simulations of some special cutting processes, such as the machining of a vibrating workpiece and a thin wall component.

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Acknowledgements

The authors are grateful for financial support from the Key National Nature Science Foundation of China (Grant No. 11132011) and the National Nature Science Foundation of China (Grant No. 11572337 and 51575029).

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Authors and Affiliations

  1. Institute of Mechanics, Chinese Academy of Sciences, Beijing, 100190, China

    Fei Shuang, Xiangyu Chen & Wei Ma

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  1. Fei Shuang
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  2. Xiangyu Chen
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  3. Wei Ma
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Correspondence to Wei Ma.

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Funding

This study was funded by the Key National Nature Science Foundation of China (grant number 11132011) and the National Nature Science Foundation of China (grant number 11572337 and grant number 51575029).

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The authors declare that they have no conflict of interest.

Electronic supplementary material

12289_2017_1341_MOESM1_ESM.avi

Video file 1. The evolution process of the equivalent plastic strain field in the cutting process with the tool chatter (AVI 2159 kb)

12289_2017_1341_MOESM2_ESM.avi

Video file 2. The evolution process of the equivalent plastic strain field in the cutting process with the large plastic deformations of structure of thin-walled components (AVI 5741 kb)

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Shuang, F., Chen, X. & Ma, W. Numerical analysis of chip formation mechanisms in orthogonal cutting of Ti6Al4V alloy based on a CEL model. Int J Mater Form 11, 185–198 (2018). https://doi.org/10.1007/s12289-017-1341-z

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