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FEA Model of Orthogonal Turning of Titanium

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

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FEA Model of Orthogonal Turning of Titanium

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

  2. 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

  3. Orthogonal Turning • Figure 1: Chip Velocity “V” is Perpendicular to Tool • Figure 2: Work Piece Velocity “Uwork” is Perpendicular to Tool Figure 1 Figure 2

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

  5. 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

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

  7. Experimental Results • Cutting Force

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

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

  10. AdvantEdge Model • Fixed Parameters

  11. AdvantEdge Model (Cont.) • Variable Parameters

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

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

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

  15. AdvantEdge Results (Cont.) • Cutting Force Comparison

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

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

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

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

  20. 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

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