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Finite element simulation of high-speed machining of titanium alloy (Ti–6Al–4V) based on ductile failure model

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Abstract

A Johnson–Cook material model with an energy-based ductile failure criterion is developed in titanium alloy (Ti–6Al–4V) high-speed machining finite element analysis (FEA). Furthermore, a simulation procedure is proposed to simulate different high-speed cutting processes with the same failure parameter (i.e., density of failure energy). With this finite element (FE) model, a series of FEAs for titanium alloy in extremely high-speed machining (HSM) is carried out to compare with experimental results, including chip morphology and cutting force. In addition, the chip morphology and cutting force variation trends under different cutting conditions are also analyzed. Using this FE model, the ductile failure parameter is modified for one time, afterword, the same failure parameter is applied to other conditions with a key modification. The predicted chip morphologies and cutting forces show good agreement with experimental results, proving that this ductile failure criterion is appropriate for titanium alloy in extremely HSM. Moreover, a series of relatively low cutting speed experiments (within the range of HSM) were carried out to further validate the FE model. The predicted chip morphology and cutting forces agree well with the experimental results. Moreover, the plastic flow trend along an adiabatic shear band is also analyzed.

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Authors and Affiliations

  1. Key Laboratory of Advanced Ceramic and Machining Technique (Tian** University), Ministry of Education, Tian**, 300072, China

    Guang Chen, Chengzu Ren, **aoyong Yang, **nmin ** & Tao Guo

  2. School of Mechanical Engineering, Tian** University, Tian**, 300072, China

    Chengzu Ren

Authors
  1. Guang Chen
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  2. Chengzu Ren
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  3. **aoyong Yang
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  4. **nmin **
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  5. Tao Guo
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Correspondence to Chengzu Ren.

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Chen, G., Ren, C., Yang, X. et al. Finite element simulation of high-speed machining of titanium alloy (Ti–6Al–4V) based on ductile failure model. Int J Adv Manuf Technol 56, 1027–1038 (2011). https://doi.org/10.1007/s00170-011-3233-6

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  • DOI: https://doi.org/10.1007/s00170-011-3233-6

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