FE analysis of the effects of process representations on the prediction of residual stresses and chip morphology in the down-milling of Ti6Al4V
| Autor: | Tahany Ibrahim El-Wardany, Nejah Tounsi |
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| Rok vydání: | 2021 |
| Předmět: |
Flank
0209 industrial biotechnology Materials science Mechanical Engineering Process (computing) Titanium alloy 02 engineering and technology Radius Edge (geometry) Chip Industrial and Manufacturing Engineering Finite element method Computer Science Applications Stress (mechanics) Micrometre 020303 mechanical engineering & transports 020901 industrial engineering & automation 0203 mechanical engineering Control and Systems Engineering Residual stress Composite material |
| Zdroj: | Journal of Manufacturing Science and Engineering. :1-50 |
| ISSN: | 1528-8935 1087-1357 |
| DOI: | 10.1115/1.4051287 |
| Popis: | Part I of these two-part papers will investigate the effect of three FEM representations of the milling process on the prediction of chip morphology and residual stresses (RS), when down-milling small uncut chips with thickness in the micrometer range and finite cutting edge radius. They are: i) orthogonal cutting with the mean uncut chip thickness t, obtained by averaging the uncut chip thickness over the cutting length, ii) orthogonal cutting with variable t, which characterizes the down-milling process and which is imposed on a flat surface of the final workpiece, and iii) modelling the true kinematics of the down milling process. The appropriate constitutive model is identified through 2D FEM investigation of the effects of selected constitutive equations and failure models on the prediction of RS and chip morphology in the dry orthogonal machining of Ti6Al4V and comparison to experimental measurements. The chip morphology and RS prediction capability of these representations is assessed using the available set of experimental data. Models featuring variable chip thickness have revealed the transition from continuous chip formation to the rubbing mode and have improved the predictions of residual stresses. The use of sequential cuts is necessary to converge toward experimental data. |
| Databáze: | OpenAIRE |
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