Experimental and FEM Study on Cutting Process of Ti-6Al-4V Alloy Titanium Concerning Tool Cutting Edge Microgeometry
The cutting tool edge radius has a major influence on the material machining process.Cutting process vari-ables such as cutting force,cutting stress and temperature distribution at the tool-chip interface,can ultimately have an effect on tool life and the integrity of the machined surface of the workpiece.The rounding passivation treatment of the cut-ting edge can make the tool less prone to chipping during the cutting process.In this study,the finite element method(FEM)is used to conduct an in-depth study of the cutting process of the rounded-edge tool.The finite element model is es-tablished by the Coupled Eulerian Lagrangian(CEL)method.In order to study the influence of the tool edge on the cutting process,the cutting conditions in this study include four tool edge radii(10μm,20μm,30μm,40μm)and three unde-formed chip thicknesses(UCT:0.1mm,0.15mm,0.2mm),the 12 kinds of working conditions are then simulated and ex-perimentally studied to verify the accuracy and rationality of the proposed finite element model.On the basis of this verifica-tion,the process quantities such as cutting temperature,cutting stress and material flow state in the simulation results are further analyzed.The temperature all showed an increasing trend,and the highest cutting temperature appeared to move from the rake face to the flank face.This research may provide support for the mechanism understanding of the titanium alloy cut-ting process and the design of tools and cutting parameters for difficult-to-machine materials.
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