FEA Model of Orthogonal Turning of Titanium

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FEA Model of Orthogonal Turning of Titanium

• December 15, 2005
• Mark Ronski

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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

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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
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Chip Serration / Segmentation

• Titanium chips have well known serration
  behavior.
• Serrations due to shear bands in chip at root of
  serration.

Shear Band
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Experimental Data

• Technical Paper
• Molinari, A. Adiabatic Shear Banding in Hign
  Speed Machining of Ti-6Al-4VExperiments 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

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Experimental Setup

• 2 Experimental Apparatus
• Universal High Speed Testing Machine (Velocity lt
  1 m/s)
• Hopkins Tube Air Gun (Velocity gt 1 m/s)

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Experimental Results

• Cutting Force

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Experimental Results (Cont.)

• Serration Frequency
• LogLog Curve Fit Slope 1.4

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AdvantEdge

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

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AdvantEdge Model

• Fixed Parameters

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AdvantEdge Model (Cont.)

• Variable Parameters

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AdvantEdge Results

• Cutting Force
• 0.25 mm/tooth Feed, 0? Clearance Angle

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AdvantEdge Results (Cont.)

• Cutting Force
• 0.12 mm/tooth Feed, 0? Clearance Angle

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AdvantEdge Results (Cont.)

• Cutting Force
• 0.12 mm/tooth Feed, 10? Clearance Angle

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AdvantEdge Results (Cont.)

• Cutting Force Comparison

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Cutting Force Variation

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

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AdvantEdge Results (Cont.)

• Chip Serration Frequency
• 0.25 mm/tooth Feed, 0? Clearance Angle

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AdvantEdge Results (Cont.)

• Chip Serration Frequency
• 0.12 mm/tooth Feed, 0? Clearance Angle

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AdvantEdge Results (Cont.)

• Chip Serration Frequency
• 0.12 mm/tooth Feed, 10? Clearance Angle

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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