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Research on breakage characteristics in side milling of titanium alloy with cemented carbide end mill

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Abstract

Titanium alloy Ti6Al4V has the advantages of high specific strength, good heat resistance, and strong corrosion resistance, which is widely used in the manufacturing of aerospace industrial parts. However, in the side milling of titanium alloy, the temperature of the cutting area is high, and the cutting edge position is prone to breakage, which affects the surface quality of the workpiece. In order to reveal the tool damage failure mechanism in the milling process of titanium alloy, firstly, the impact force model when the tool cuts into the workpiece from the empty stroke and the milling force model during milling are established to obtain the cyclic load characteristics and impact effect of the tool. Then, based on the fatigue crack propagation theory and the energy balance equation of sliding crack, the elastic modulus and crack propagation law of tool material under different cutting impacts are analyzed. The interval method is used to recalculate the initial and critical damage value of tool material fracture in the maximum range. Finally, the limit conditions of the edge impact fracture of the end mill are established, and the safe cutting area of tool breakage is redefined. Through the milling test of titanium alloy, the impact damage morphology of tool in different states is redefined. The obtained redefined tool safety area provides a theoretical basis for high-speed and high-efficiency milling of titanium alloy, tool breakage, and tool life.

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Data Availability

The datasets used or analyzed during the current study are available from the corresponding author on reasonable request.

Abbreviations

h :

The thickness of the undeformed chip

A e :

The cutting width

τ 0 :

The shear stress at the shear exit

σ n :

The normal stress

ϕ n :

The normal shear angle

F ns :

The normal pressure

F s :

The shear force

F f :

The frictional force

F n :

The positive pressure

Hv :

The Rockwell hardness of the material

L 1 :

The bonding zone length of the rake face

L :

The tool-chip contact length

V c :

The chip velocity

T :

The average temperature on the rake face

T m :

The melting point temperature of the workpiece material

VB :

The flank wear volume

VB * :

The constant width of elastic contact zone

τ 1 :

The maximum shear stress of flank face

σ 1 :

The maximum normal stress of flank face

μ :

The friction coefficient

α n :

The normal rake angle

η c :

The chip outflow angle

λ s :

The inclination angle

F tw :

The tangential force on the flank face

F rw :

The radial force on the flank face

dF t :

The tangential force

dF r :

The radial force

dF a :

The axial force

β :

Helix angle of end mills

R :

The radius of end mills

F n1 :

The normal contact force

F s1 :

The tangential contact force

R 1, R 2 :

The effective collision radii of two collision objects

u 1, u 2 :

The Poisson's ratio of the matrix material

K a :

The stiffness coefficient

δ :

The deformation of the collision object

e :

The index of penetration depth

\( \dot{\delta} \) :

The relative velocity of the two objects

u :

The hysteretic damping factor

ε :

The ratio of normal relative velocity

E a1, E a2 :

The three-dimensional elastic modulus

F im,x :

The impact force in X direction

F im,y :

The impact force in Y direction

A u :

The material unit area.

D :

The damage value of tool material

φ f :

The contact angle during the collision

σ * :

The damage equivalent stress

σ :

The triaxial stress

v :

The Poisson's ratio of tool material

σ c :

The uniaxial compressive stress

ε 1 e, ε 2 e :

The elastic strain of the non-damaged tool material

Δε 1, Δε 2 :

The elastic strain of the non-damaged tool material

σ 1, σ 2 :

The normal stress in two directions

W e :

The elastic strain energy caused by the open crack propagation

W f :

The frictional energy caused by the initial microcracks

W 1 :

The work done caused by the uniaxial compressive stress

E :

The elastic modulus of tool material

K :

The parameter determined by Poisson's ratio

K l :

The stress intensity factor of the crack array

l n :

The length of the nth impact cracks

2w :

The spacing between microcracks

n :

The number of stress cycles or the number of cutting of each tooth

∆K :

The stress intensity factor

τ f :

The shear traction on the crack surface

χ :

The sliding distance of the initial microcrack faces

l 0 :

The initial damage value of tool material

\( {\dot{l}}_0 \) :

The initial crack propagation rate

l n :

The crack propagation length

D n :

The damage value of tool material

f 0 :

The density of the initial microcrack

N 0 :

The number of initial microcracks in the unit area

P :

The porosity of cemented carbide

ρ :

The actual density of cemented carbide

ρ 0 :

The nominal density of cemented carbide

2a, 2b :

The lengths of the selected unit

2c :

The length of initial microcracks

l :

The length of each open crack

θ en :

The cutting entry angles

θ ex :

The cutting exit angle

Δt :

The effective cutting time

t :

The cutting time

F zong :

The overall impact force

G :

The shear modulus of cemented carbide tools

γ :

The shear strain of cemented carbide

A :

The cross-sectional area of the fracture

VB po :

The width of tool flank breakage

a p :

The cutting depth

ξ :

The impact stress

[τ]:

The allowable stress

E D :

The elastic modulus after tool damage

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Funding

This project is supported by the Projects of International Cooperation and Exchanges NSFC (Grant Number 51720105009), the National Key Research and Development Project (Grant Number 2018YFB2002201), and the Outstanding Youth Fund of Heilongjiang Province (Grant Number YQ2019E029).

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Authors and Affiliations

  1. Key Laboratory of Advanced Manufacturing and Intelligent Technology, Ministry of Education, Harbin University of Science and Technology, Harbin, 150080, China

    Yanjie Du, Caixu Yue, Xiaochen Li & Xianli Liu

  2. George W. Woodruff School of Mechanical Engineering, Georgia Institute of Technology, Atlanta, GA, USA

    Steven Y. Liang

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  1. Yanjie Du
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  2. Caixu Yue
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  3. Xiaochen Li
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Contributions

Caixu Yue put forward the theme of the paper and established the structure of the paper; Yanjie Du established the damage model and processed the simulation data; Xiaochen Li verified the model, and processed the experimental data; Xianli Liu and Steven Y. Liang examined the overall structure of the paper and made suggestions on the details of the paper.

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Correspondence to Caixu Yue.

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Du, Y., Yue, C., Li, X. et al. Research on breakage characteristics in side milling of titanium alloy with cemented carbide end mill. Int J Adv Manuf Technol 117, 3661–3679 (2021). https://doi.org/10.1007/s00170-021-07938-y

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