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Modeling of contact stress and tool-based frictional forces considering edge effect in cutting Ti-6Al-4 V

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Abstract

Cutting tools with round edge can enhance the performance of machining difficult-to-machine materials, while the complex contact mechanism related to micro cutting edge limits the deeper understanding of cutting mechanics. Material separation, which is associate to plough mechanism with formation of dead metal zone (DMZ), also requires the analysis of contact behavior. This study develops a contact model along the round edge together with the illustration of DMZ, with three contact feature points defined to explain the contact situation between workpiece and cutting edge. Among these feature points, two separation points related to DMZ classify the sliding and sticking region considering the dual-zone approach. The stagnation point is the zero shear stress point where a sudden change in shear stress direction happens. Besides, the parabolic stress model obtained from finite element simulations is established to define the normal contact distribution along the round edge. In this basis, the tool-based cutting forces are predicted with proposed contact model and two contact force components are classified for different contact regions. The proposed contact feature points and contact stress are validated through illustration with finite element simulations. Besides, orthogonal cutting tests ensure the practicality and accuracy of the proposed contact model and predicted cutting forces.

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Funding

This work is partially supported by the State Key Laboratory of Digital Manufacturing Equipment and Technology (DMETKF2021005) and the Fundamental Research Funds for the Central Universities (WUT: 2021III025JC).

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Authors and Affiliations

  1. Hubei Digital Manufacturing Key Laboratory, School of Mechanical and Electronic Engineering, Wuhan University of Technology, Wuhan, 430070, China

    Weiwei Zhang, Jian Weng, Kejia Zhuang, Cheng Hu & Chaoqun Wu

  2. State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan, China

    Xing Dai

Authors
  1. Weiwei Zhang
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  2. Jian Weng
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  3. Kejia Zhuang
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  4. Cheng Hu
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  5. Xing Dai
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  6. Chaoqun Wu
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Contributions

Weiwei Zhang: writing original draft, methodology, validation and investigation. Jian Weng: writing—review and editing, validation. Kejia Zhuang: supervision, writing—review and editing, review of experimental setup. Cheng Hu: investigation. Xing Dai: investigation. Chaoqun Wu: supervision, investigation.

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Correspondence to Kejia Zhuang.

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Zhang, W., Weng, J., Zhuang, K. et al. Modeling of contact stress and tool-based frictional forces considering edge effect in cutting Ti-6Al-4 V. Int J Adv Manuf Technol 118, 2405–2418 (2022). https://doi.org/10.1007/s00170-021-08103-1

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  • DOI: https://doi.org/10.1007/s00170-021-08103-1

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