FEA Model of Orthogonal Turning of Titanium December 15, 2005 Mark Ronski

Project Overview Open Ended Project Use Third Wave Systems AdvantEdge Software Model Orthogonal Turning of Titanium Problem Statement 2-D Orthogonal Turning of Ti-6Al-4V Determine Cutting Force and Chip Serration Frequency

Orthogonal Turning Figure 1: Chip Velocity “V” is Perpendicular to Tool Figure 2: Work Piece Velocity “U work ” is Perpendicular to Tool Figure 1Figure 2

Chip Serration / Segmentation Titanium chips have well known serration behavior. Serrations due to shear bands in chip at root of serration. Shear Band

Experimental Data Technical Paper Molinari, A. Adiabatic Shear Banding in Hign Speed Machining of Ti-6Al-4V:Experiments and Modeling. International Journal of Plasticity. Purpose to Examine Sear Bands in Ti-6Al-4V Chip Experimental Results For… Longitudinal Cutting Force Chip Serration/Segmentation Frequency

Experimental Setup 2 Experimental Apparatus Universal High Speed Testing Machine (Velocity < 1 m/s) Hopkins Tube Air Gun (Velocity > 1 m/s)

Experimental Results Cutting Force

Experimental Results (Cont.) Serration Frequency Log–Log Curve Fit Slope ≈ 1.4

AdvantEdge Finite Element Software Highly Automated Meshing Material Libraries for Work piece and Tool Standard Tool Geometry Library User Defines Cutting Parameters

AdvantEdge Model Fixed Parameters Work Piece Properties Height “h” (mm)2 Length “L” (mm)15 MaterialTi-6Al-4V Tool Parameters MaterialCarbide-General Rake Angle “a” (Degrees)0 Cutting Radius “r” (mm)0.02 Process Parameters Depth of Cut “doc” (mm)1 Length of Cut “loc” (mm)12 Initial Temperature (Degrees C)20

AdvantEdge Model (Cont.) Variable Parameters Cutting Velocity (m/s) Clearance Angle (Deg.) Feed (mm/tooth) Run A1, 5, 20, 40, 60, Run B1, 5, 20, 40, 60, Run C1, 5, 20, 40, 60,

AdvantEdge Results Cutting Force 0.25 mm/tooth Feed, 0  Clearance Angle

AdvantEdge Results (Cont.) Cutting Force 0.12 mm/tooth Feed, 0  Clearance Angle

AdvantEdge Results (Cont.) Cutting Force 0.12 mm/tooth Feed, 10  Clearance Angle

AdvantEdge Results (Cont.) Cutting Force Comparison

Cutting Force Variation Reason For Cutting Force Variation Unknown All Runs Showed Similar Tool and Model… Stress Plastic Strain Temperature

AdvantEdge Results (Cont.) Chip Serration Frequency 0.25 mm/tooth Feed, 0  Clearance Angle

AdvantEdge Results (Cont.) Chip Serration Frequency 0.12 mm/tooth Feed, 0  Clearance Angle

AdvantEdge Results (Cont.) Chip Serration Frequency 0.12 mm/tooth Feed, 10  Clearance Angle

Conclusion Advantage Showed Excellent Agreement with Experimental Serration Frequency for 0.12 mm/tooth Feed Advantage Showed Good Cutting Force Trend for 10  Clearance Angle Poor Results for ~0  Clearance Angle