Abstract
The excellent mechanical and physical properties of Ti6Al4V titanium alloy make it a good candidate material for a broad range of applications, with special relevance for the aerospace industry. As a difficult-to-cut alloy, it represents a great challenge to improve its machinability and surface integrity while simultaneously avoiding the high time consuming and cost of the experiments. Modelling and simulation of the machining process offer a cost-effective method to investigate the machining process. In this work, an orthogonal cutting model of Ti-6Al-4 V alloy was developed and used to simulate the major cutting outcomes, including: forces, temperature distribution, chip geometry, chip compression ratio and residual stresses in the machined surface and subsurface. This cutting model includes a constitutive model accounting for the state of stress and the strain-rate effects on the mechanical behaviour (plasticity and damage) of Ti-6Al-4 V alloy in metal cutting. In addition, Zorev contact model is used to simulate the contact stresses at both tool-chip and tool-workpiece interfaces. The proposed cutting model could predict relatively well the major cutting outcomes for seven cutting conditions. The difference between simulated and experimental cutting forces is less than 14%, but the predicted thrust force is underestimated about 53% in maximum. The difference between simulated and measured maximum compressive residual stresses in cutting and transversal directions can reach in average about 17% and 36%, respectively. The maximum difference between predicted and measured thicknesses of the layer affected by residual stresses is less than 19%. This study highlights several critical points affecting the thrust force and the residual stress predictions, which should be considered in future developments of cutting models.
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Acknowledgements
The authors would like to thank Dr. Bertrand Marcon from Arts & Metiers Institute of Technology for his help in the digital image correlation system.
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The research work presented in the article was financially supported by Seco Tools and Safran companies and China Scholarships Council program (No. 201606320213).
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Cheng, W., Outeiro, J.C. Modelling orthogonal cutting of Ti-6Al-4 V titanium alloy using a constitutive model considering the state of stress. Int J Adv Manuf Technol 119, 4329–4347 (2022). https://doi.org/10.1007/s00170-021-08446-9
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DOI: https://doi.org/10.1007/s00170-021-08446-9