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3D FEM simulation of helical milling hole process for titanium alloy Ti-6Al-4V

  • Chunhui Ji
  • Yonghang Li
  • Xuda QinEmail author
  • Qing Zhao
  • Dan Sun
  • Yan Jin
ORIGINAL ARTICLE

Abstract

As an emerging hole-machining methodology, helical milling process has become increasingly popular in aeromaterials manufacturing research, especially in areas of aircraft structural parts, dies, and molds manufacturing. Helical milling process is highly demanding due to its complex tool geometry and the progressive material failure on the workpiece. This paper outlines the development of a 3D finite element model for helical milling hole of titanium alloy Ti-6Al-4V using commercial FE code ABAQUS/Explicit. The proposed model simulates the helical milling hole process by taking into account the damage initiation and evolution in the workpiece material. A contact model at the interface between end-mill bit and workpiece has been established and the process parameters specified. Furthermore, a simulation procedure is proposed to simulate different cutting processes with the same failure parameters. With this finite element model, a series of FEAs for machined titanium alloy have been carried out and results compared with laboratory experimental data. The effects of machining parameters on helical milling have been elucidated, and the capability and advantage of FE simulation on helical milling process have been well presented.

Keywords

Finite element model Helical milling hole 3D Titanium alloy 

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Copyright information

© Springer-Verlag London 2015

Authors and Affiliations

  • Chunhui Ji
    • 1
  • Yonghang Li
    • 1
  • Xuda Qin
    • 1
    Email author
  • Qing Zhao
    • 1
  • Dan Sun
    • 2
  • Yan Jin
    • 2
  1. 1.Tianjin Key Laboratory of Equipment Design and Manufacturing TechnologyTianjin UniversityTianjin CityPeople’s Republic of China
  2. 2.School of Mechanical and Aerospace EngineeringQueen’s UniversityBelfastUK

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