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Machining mechanism and stress model in cutting Ti6Al4V

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Abstract

In the aircraft industry, Ti6Al4V is often used due to its good strength and excellent comprehensive performance. However, because of its particularity, the titanium alloy material itself makes the processing difficult. In the current research, the research on the force of machining, heat flow, and stress on machined surfaces produced when machining titanium alloy is not enough, especially for the residual stress has not been able to give a more accurate numerical solution. The main work of this essay includes the following: a planar orthogonal cutting model is established by finite element method (FEM), and the cutting mechanism is studied based on the established model. Combining previous work, the cutting temperature model was analyzed and the relationship between the distance from machined surface and residual temperature of the processed workpiece is discussed. Simulations are performed on the cutting temperature field under different processing conditions. Furthermore, on the basis of the model of cutting force and temperature, it was proposed that the residual stress versus depth curve can be an exponential function and a linear superposition of high-order Gaussian functions. This research has certain significance in revealing the mechanism of cutting force and residual stress formation in difficult-to-machine materials.

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Abbreviations

\({\tau }_{s}\) :

Flow stress in primary shear band (MPa)

\(\upvarepsilon\) :

Equivalent plastic strain

\({\varepsilon }{\prime}\) :

Equivalent plastic strain rate (s−1)

\({\varepsilon }_{0}{\prime}\) :

Equivalent plastic strain rate (s−1)

\(\mathrm{T}\) :

Workpiece temperature \(\left(\mathrm{^\circ{\rm C} }\right)\)

Tm :

Material melting temperature \(\left(\mathrm{^\circ{\rm C} }\right)\)

Tr :

Room temperature \((\mathrm{^\circ{\rm C} })\)

\({\gamma }_{o}\) :

Rake angle \(\left(^\circ \right)\)

t:

Cut thickness (mm)

rz :

Cutting edge radius (mm)

\({F}_{\tau s}\) :

Resultant force (N)

\({F}_{\tau }\) :

Shear force (N)

\({F}_{\tau n}\) :

Normal force perpendicular to shear plane (N)

\({F}_{f}\) :

Sliding friction force on tool-chip interface (N)

\({F}_{n}\) :

Normal force perpendicular to back chip (N)

\(\Phi\) :

Shear angle \((^\circ )\)

\(\upbeta\) :

Friction angle \((^\circ )\)

\({\alpha }_{p}\) :

Cutting depth (mm)

tc :

Chip thickness (mm)

Fc :

Cutting force (N)

\(\mathrm{v}\) :

Cutting speed

\({v}_{c}\) :

Chip flow velocity

\({v}_{s}\) :

Shear velocity

w:

Width of cutting (mm)

h:

Thickness of primary shear band (mm)

L:

Length of shear band (mm)

\({T}_{M(x,z)}^{s}\) :

Total temperature rise of point M caused by the shear heat source \((\mathrm{^\circ{\rm C} })\)

Tp :

Temperature rise of point M caused by the shear heat source \((\mathrm{^\circ{\rm C} })\)

Ti :

Temperature rise of point M caused by imaginary heat source \(\left(\mathrm{^\circ{\rm C} }\right)\)

B:

Fraction of shear plane heat conducted into workpiece

qs :

Heat liberation intensity of shear plane

\(\uplambda\) :

Thermal conductivity (w/(mm \(\mathrm{^\circ{\rm C} }\)))

\(\mathrm{a}\) :

Thermal diffusivity (mm2/s)

\({K}_{0}\) :

Modified Bessel function of second kind of order zero

\({K}_{w}^{s}\) :

Dimensionless coefficient of modification of K0, corresponding to shear plane heat source

\({\rho }_{s}\) :

Heating time of point M(x, z) due to shear plane heat source (s)

\({\rho }_{f}\) :

Heating time of point M(x, z) due to tool flank-workpiece rubbing heat source (s)

\({T}_{M(x,z)}^{F}\) :

Temperature rise of point M caused by the tool-workpiece friction heat source \((\mathrm{^\circ{\rm C} })\)

\({q}_{F}\) :

Heat liberation intensity of tool-workpiece friction zone

VB:

Width of tool-workpiece contact zone (mm)

BF :

Fraction of tool-workpiece rubbing heat conducted into workpiece

\({K}_{w}^{F}\) :

Dimensionless coefficient of modification of K0, corresponding to shear plane heat source

\({T}_{M\left(x,z\right)}\) :

Final temperature rise of point M(x, z) \(\left(\mathrm{^\circ{\rm C} }\right)\)

\({\sigma }^{f-mech}\) :

Stress due to cutting force

\({\sigma }^{w-mech}\) :

Stress due to flank wear width

\({\tau }^{f-mech}\) :

Shear stress due to cutting force

\({\tau }^{mech}\) :

Shear stress due to flank wear width

\({\sigma }^{mech}\) :

Stress due to thermal stress

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Funding

This study was supported by a research project financed by the National Natural Science Foundation of China (Number 5217052158).

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Authors and Affiliations

  1. Shanghai University of Engineering Science, Shanghai, 201620, China

    Shujing Wu, Dazhong Wang & Guoqiang Wang

  2. Shanghai Tobacco Machinery Co., Ltd, Shanghai, 201206, China

    Feiyang Chen

  3. Qingdao University of Technology, Qingdao, 266520, China

    Changhe Li

  4. Jiangsu University, Zhenjiang, 212013, China

    Jinzhong Lu

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  1. Shujing Wu
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Contributions

Conceptualization, Shujing Wu; software, Feiyang Chen and Dazhong Wang; editing, Guoqiang Wang; writing review, Change Li and Jinzhong Lu. All authors have read and agreed to the published version of the manuscript.

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Correspondence to Dazhong Wang.

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Wu, S., Chen, F., Wang, D. et al. Machining mechanism and stress model in cutting Ti6Al4V. Int J Adv Manuf Technol 131, 2625–2639 (2024). https://doi.org/10.1007/s00170-023-11941-w

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