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Analytical modeling of machining forces of ultra-fine-grained titanium

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Abstract

In this work, the machining of ultra-fine-grained pure titanium (UFG Ti) in an integrated manufacturing process combining severe plastic deformation (SPD) process and machining process is investigated through analytical modeling with experimental validation. UFG Ti is increasing finding usefulness in lightweight engineering applications and biomedical applications because of its sufficient mechanical strength, manufacturability, and biocompatibility. The UFG Ti is prepared by a SPD process, namely equal channel angular extrusion (ECAE) from commercial pure grade 4 titanium. However, the machining process in the integrated manufacturing process has not been fully understood in the context of machining forces and temperatures. The machining forces are predicted in this work using extended chip formation model. In this model, the average temperature at the primary shear zone is calculated based on the equilibrium between generated heat and plastic work. Orthogonal cutting tests were conducted under various cutting conditions with experimental force measurements using a piezoelectric dynamometer. Good agreements are observed between predicted forces and experimental forces. In addition, sensitivity analyses were performed to investigate the influence of input J-C constants and cutting condition parameters on the accuracy of the predicted machining forces. The predicted machining forces were compared to machining forces of Ti-6Al-4V alloy under various cutting conditions, which are widely used in engineering and biomedical applications. This work extends the applicability of analytical models in machining to a broader class of materials. It will promote the use of UFG Ti and the integrated manufacturing process in engineering and biomedical applications.

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Authors and Affiliations

  1. George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, 801 Ferst Drive, Atlanta, GA, 30332-0405, USA

    Jinqiang Ning, Vinh Nguyen & Steven Y. Liang

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  1. Jinqiang Ning
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  2. Vinh Nguyen
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  3. Steven Y. Liang
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Correspondence to Jinqiang Ning or Steven Y. Liang.

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Ning, J., Nguyen, V. & Liang, S.Y. Analytical modeling of machining forces of ultra-fine-grained titanium. Int J Adv Manuf Technol 101, 627–636 (2019). https://doi.org/10.1007/s00170-018-2889-6

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  • DOI: https://doi.org/10.1007/s00170-018-2889-6

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