ACTA AERONAUTICAET ASTRONAUTICA SINICA >
FEM Estimation of Tool Wear in High Speed Cutting of Ti6Al4V Alloy
Received date: 2013-04-12
Revised date: 2013-06-13
Online published: 2013-06-21
Supported by
National Natural Science Foundation of China (50775115
By adopting the finite element method (FEM), the tool wear is simulated during the cutting of titanium alloy with a carbide tool. First, a wear rate model, which includes the abrasive wear, diffusion wear and adhesion wear, is built according to the tool wear mechanism during the cutting. Then a series of problems in tool wear simulation are solved such as the simulation of the cutting temperature field, adjustment of internal mesh, and the smoothing of tool geometry. Subsequently, an FEM wear prediction model is built and computed in combination with a wear subroutine. The validity of the finite element model is confirmed by cutting tests, which show that the tool rake face wear and wear morphology can be accurately predicted by the finite element model. Finally, tool life is predicted under the conditions of high-speed cutting of titanium alloys. The prediction results show that the cutting tools wear rapidly with the increase of the cutting speed. For example, the tool life with a cutting speed of 300 m/min is only one third of that with a speed of 130 m/min. Therefore, it is important to consider both cutting efficiency and tool life simultaneously in the selection of a cutting speed.
Key words： high speed cutting; titanium alloys; tool wear; FEM; wear rate model
CHEN Yan , YANG Shubao , FU Yucan , XU Jiuhua , SU Honghua . FEM Estimation of Tool Wear in High Speed Cutting of Ti6Al4V Alloy[J]. ACTA AERONAUTICAET ASTRONAUTICA SINICA, 2013 , 34(9) : 2230 -2240 . DOI: 10.7527/S1000-6893.2013.0306
[1] Arrazola P J, Garay A, Iriarte L M, et al. Machinability of titanium alloys (Ti6Al4V and Ti555.3). Journal of Materials Processing Technology, 2009, 209(5): 2223- 2230.
[2] Yang X, Liu R C. Machining titanium and its alloys. Machining Science and Technology, 1999, 3(1): 107-139.
[3] Su H H, Liu P, Fu Y C, et al. Tool life and surface integrity in high-speed milling of titanium alloy TA15 with PCD/PCBN tools. Chinese Journal of Aeronautics,2012, 25(5): 784-790.
[4] Taylor F W. On the art of cutting metals. New York: The American Society of Mechanical Engineers, 1907: 31-35.
[5] Hastings W F, Mathew P, Oxley P L B, et al. Estimated cutting temperatures their use as a predictor of tool performance when machining plain carbon steels. Proceedings of the 20th International Machine Tool Design and Research Conference, 1979: 313-320.
[6] Usui E, Shirakashi T, Kitagawa T. Analytical predication of cutting tool wear. Wear, 1984, 100(1-3): 129-151.
[7] Takeyama H, Murata R. Basic investigation of tool wear. Journal of Engineering for Industry, 1963, 85 (1): 33-37.
[8] Kitagawa T, Maekawa K, Shirakashi T, et al. Analytical prediction of flank wear of carbide tools in turning plain carbon steels (Part 1) characteristic equation of flank wear. Bulletin of the Japan Society of Precision Engineering, 1988, 22 (4): 263-269.
[9] Yen Y C, Sohner J, Lilly B, et al. Estimation of tool wear in orthogonal cutting using the finite element analysis. Journal of Materials Processing Technology, 2004, 146(1): 82-91.
[10] Xie L J, Schmidt J, Schmidt C, et al. 2D FEM estimate of tool wear in turning operation. Wear, 2005, 258(10): 1479-1490.
[11] Attanasio A, Ceretti E, Rizzuti S, et al. 3D finite element analysis of tool wear in machining. CIRP Annals-Manufacturing Technology, 2008, 57(1): 61-64.
[12] Attanasio A, Ceretti E, Fiorentino A, et al. Investigation and FEM-based simulation of tool wear in turning operations with uncoated carbide tools. Wear, 2010, 269(5-6): 344-350.
[13] Filice L, Umbrello D, Micari F. FE analyses of tool wear in orthogonal cutting. Proceedings of the Second International Conference on Tribology in Manufacturing Processes, 2004: 187-194.
[14] Filice L, Micari F, Settineri L, et al. Wear modeling in mild steel orthogonal cutting when using uncoated carbide tools. Wear, 2007, 262(5-6): 545-554.
[15] Wang M. Studies on tool wear in milling of titanium alloys. Nanjing: Nanjing Aeronautical Institute, 1985. (in Chinese) 王珉. 钛合金铣削加工中刀具磨损的研究. 南京: 南京航空学院, 1985.
[16] Rabinowicz E, Dunn L A, Russell P G. A study of abrasive wear under three-body conditions. Wear, 1961, 4(5): 345-355.
[17] Archard J F. Contact and rubbing of flat surfaces. Journal of applied physics, 1953, 24(8): 981-988.
[18] Childs T. Metal machining: theory and applications. London: Butterworth-Heinemann, 2000: 77-79.
[19] Shi D F. FEM simulation of tool wear in high speed cutting of titanium alloy Ti6Al4V with hydrogen treatment. Nanjing: College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics & Astronautics, 2010. (in Chinese) 史德峰. 置氢钛合金TC4高速切削刀具磨损有限元仿真分析. 南京: 南京航空航天大学机电学院, 2010.
[20] Yang S B, Xu J H, Wei W H, et al. Impact of hydrogenation on flow behavior of Ti6Al4V alloy. Acta Aeronautica et Astronautica Sinica, 2010, 31(5): 1093-1098. (in Chinese) 杨树宝, 徐九华, 危卫华,等. 置氢处理对TC4钛合金流变行为的影响. 航空学报, 2010, 31(5): 1093-1098.
[21] Zorev N N. Inter-relationship between shear processes occurring along the tool face and shear plane in metal cutting. International Research in Production Engineering, New York: The American Society of Mechanical Engineers, 1963: 42-49.
[22] Kloche F, Raedt H W, Hoppe S. 2D-FEM simulation of the orthogonal high speed cutting process. Machining Science and Technology, 2001, 5(3):323-340.
[23] Umbrello D. Finite element simulation of conventional and high speed machining of Ti6Al4V alloy. Journal of Materials Processing Technology, 2008, 196(1-3): 79-87.
[24] Wei W H, Fundamental research on machinability of titanium alloy by thermohydrogen treatment. Nanjing: College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics & Astronautics, 2010. (in Chinese) 危卫华. 热氢处理改善钛合金切削加工性的基础研究. 南京: 南京航空航天大学机电学院, 2010.
/
| 〈 |
|
〉 |
CJA