Simulation model of cutting force in helical milling hole of titanium alloy based on material damage evolution

Abstract

Abstract: Cutting force simulation is an effective way to reduce experimental verification costs and optimize process parameters. The material damage process is difficult to describe and the grid distortion is serious in the 3D simulation of helical milling hole. In order to solve this problems, the evolution mode of fracture energy is defined as exponential evolution, the physical separation criterion was adopted and the fracture energy parameter was determined to be 44 350 N/m. Combined with the range of axial and tangential feed in the machining cycle, the meshing parameters were set and the 3D finite element model of unit period of revolution in the stable machining stage of helical milling hole was constructed. The results show that the fracture energy and meshing parameters can effectively improve the accuracy of cutting force simulation model. The average values of axial cutting force and tangential cutting force of helical milling are 91.7% and 92% of the experimental values, respectively, with the maximum error less than 9%. The model also shows strong can also be applied to the simulation of cutting force in helical milling with different cutter teeth (single, two, three and four teeth) and the same geometry of mills.

Key words: helical milling hole, finite element model, damage evolution, cutting force

CLC Number:

TH123

LI Wei, ZHOU Lan, WANG Lin-jun, AN Guo-sheng, FENG Li, FENG Zhao-he. Simulation model of cutting force in helical milling hole of titanium alloy based on material damage evolution[J]. Journal of Lanzhou University of Technology, 2023, 49(2): 56-64.

References

[1] WANG Y Q,LIU J X,LIU K,et al.Modeling of temperature distribution in turning of Ti-6Al-4V with liquid nitrogen cooling [J].International Journal of Advanced Manufacturing Technology,2020,107(1/2):451-462.
[2] 陈剑虹,肖乐,陈永庆,等.热等静压保温温度对TC4合金组织及拉伸性能的影响 [J].兰州理工大学学报,2021,47(1):1-4.
[3] RASHID R A,MURAD M N,HAMIDON R,et al.Experimental investigation of machining parameter on hole quality in drilling Ti-6Al-4V [J].IOP Conference Series:Materials Science and Engineering,2020,932(1):012128.
[4] KUMAR A,BHARDWAJ R,JOSHI S S.Thermal modeling of drilling process in titanium alloy (Ti-6Al-4V) [J].Machining Science and Technology,2020,24(3):341-356.
[5] DEHGHAN S,SOURY E,ISMAIL M I S B.A comparative study on machining and tool performance in friction drilling of difficult to machine materials AISI304,Ti-6Al-4V,Inconel718 [J].Journal of Manufacturing Processes,2021,61:128-152.
[6] BARMAN A,ADHIKARI R,BOLAR G.Evaluation of conventional drilling and helical milling for processing of holes in titanium alloy Ti6Al4V [J].Materials Today:Proceedings,2020,28(4):2295-2300.
[7] SHAN C W,ZHANG X,SHEN B,et al.An improved analytical model of cutting temperature in orthogonal cutting of Ti6Al4V[J].Chinese Journal of Aeronautics,2019,32(3):759-769.
[8] 杨国林,董志刚,康仁科,等.螺旋铣孔技术研究进展 [J].航空学报,2020,41(7):18-32.
[9] 陈光,刘见,戈家影,等.基于运动学及力热分析的CFRP超声振动辅助螺旋铣孔质量影响机制 [J].机械工程学报,2021,57(1):199-209.
[10] 董志刚,高宇,康仁科,等.钛合金螺旋铣孔孔径偏差研究 [J].航空学报,2021,42(3):414-422.
[11] 王海艳,陶克新,金天.球头铣刀螺旋铣孔材料去除及孔形成过程分析 [J].东北大学学报(自然科学版),2020,41(11):1602-1608.
[12] ZHOU L,AN G S,LI W S,et al.Study of undeformed chip and cap geometries at three machining stages in the orbital drilling process [J].International Journal of Advanced Manufacturing Technology,2019,104(5/6/7/8):2429- 2445.
[13] ZHOU L,DONG H Y,KE Y L,et al.Analysis of the chip-splitting performance of a dedicated cutting tool in dry orbital drilling process [J].International Journal of Advanced Manufacturing Technology,2017,90(5/6/7/8):1809-1823.
[14] ZHOU L,AN G S,LI W S,et al.Unified plastic limit analysis of the cap bottom generated by a dedicated cutting tool in orbital drilling [J].International Journal of Advanced Manufacturing Technology,2021,115(9/10):3301-3315.
[15] 万敏,杜宇轩,张卫红,等.单向CFRP螺旋铣削力建模 [J].航空学报,2021,42(10):277-291.
[16] 王海艳,王健宇,陶克新.碳纤维复合材料螺旋铣孔瞬时切削力系数识别 [J].东北大学学报(自然科学版),2020,41(10):1432-1437.
[17] 魏敏,秦旭达.基于切削建模的螺旋铣孔刀具角度优化 [J].天津工业大学学报,2012,31(1):85-88.
[18] WANG H Y,QIN X D,REN C Z,et al.Prediction of cutting forces in helical milling process [J].International Journal of Advanced Manufacturing Technology,2012,58(9/10/11/12):849-859.
[19] LIU C Y,WANG G,DARGUSCH M S.et al.Modelling simulation and experimental investigation of cutting forces during helical milling operations [J].International Journal of Advanced Manufacturing Technology,2012,63(9/10/11/12):839-850.
[20] DAVOUDINEJAD A,PARENTI P,ANNONI M.3D finite element prediction of chip flow,burr formation,and cutting forces in micro end-milling of aluminum 6061-T6 [J].Frontiers of Mechanical Engineering,2017,12(2):203-214.
[21] RASTI A,SADEGHI M H,FARSHI S S.Finite element prediction of fatigue lifetime for different hole making strategies [J].Journal of Mechanical Science and Technology,2019,33(11):5227-5233.
[22] ÖZEL T,OLLEAK A,THEPSONTHI T.Micro milling of titanium alloy Ti-6Al-4V:3D finite element modeling for prediction of chip flow and burr formation [J].Production Engineering,2017,11(415):435-444.
[23] 李永行.钛合金螺旋铣孔过程仿真与试验研究 [D].天津:天津大学,2014.
[24] 张恒.难加工材料螺旋铣孔的数值模拟与实验研 [D].杭州:浙江大学,2014.
[25] JI C H,LI Y H,QIN X D,et al.3D FEM simulation of helical milling hole process for titanium alloy Ti-6Al-4V [J].The International Journal of Advanced Manufacturing Technology,2015,81(9/10/11/12):1733-1742.
[26] 陈哲.基于ABAQUS仿真的钛合金螺旋铣孔工艺参数对孔质量的研究 [D].天津:天津工业大学,2018.
[27] 刘倩.钛合金螺旋铣孔有限元分析与实验研究 [D].哈尔滨:哈尔滨工业大学,2016.
[28] ISBILIR O,GHASSEMIEH E.Evaluation of drilling process in Ti6Al4V using 3D FE simulation [J].International Journal of Machining and Machinability of Materials,2013,13(2/3):174-190.
[29] WU H B,ZHANG S J.3D FEM simulation of milling process for titanium alloy Ti6Al4V [J].International Journal of Advanced Manufacturing Technology,2014,71(5/6/7/8):1319-1326.
[30] 赵家黎,邵坤鹏,张盼盼,等.基于J-C本构模型的2A12铝合金高速铣削特性研究 [J].兰州理工大学学报,2021,47(6):45-49.
[31] SONG X H ,LI A H,LV M H,et al.Finite element simulation study on pre-stress multi-step cutting of Ti-6Al-4V titanium alloy [J].International Journal of Advanced Manufacturing Technology,2019,104(4):2761-2771.
[32] ZHANG Y C,OUTEIRO J C,MABROUKI T.On the selection of Johnson-Cook constitutive model parameters for Ti-6Al-4V using three types of numerical models of orthogonal cutting [J].Procedia CIRP,2015,31:112-117.
[33] HILLERBORG A,MODÉER M,PETERSSON P E.Analysis of crack formation and crack growth in concrete by means of fracture mechanics and finite elements [J].Cement and Concrete Research,1976,6(6):773-781.
[34] ZHANG Y C,MABROUKI T,NELIAS D.FE-model for Titanium alloy (Ti-6Al-4V) cutting based on the identification of limiting shear stress at tool-chip interface [J].International Journal of Material Forming,2011,4(1):11-23.
[35] 刘鸣放,刘胜新.金属材料力学性能手 [M].北京:机械工业出版社,2011:242-245.