Hi everyone,
I'm performing 2D Orthogonal turning of Ti6Al4V sample, although I'm able to see chip formation and run the model smoothly but I can't seem to get serrated chips which actually is my objective.
Cutting Speed : 50m/min, 120m/min & 240m/min.
Feed : 100 microns
Mesh element : CPE4RT
WP & Tool are both 2D planar shells.
I have attached the photos of my modelling herewith. Please help
Dear Amal. I comment in your question only from experimental point of view.
The chip shape in Ti alloy is normally serrated, but there are some variables that could make bigger this process. For example utilize a tool with a negative rake angle.
In another sense, the cutting speed for machining Ti alloy is between 40-70 m/min with hard metal insert.
And what about the feed? This parameter take values between 0,1 a 0,4 mm/v in turning process.
I hope these comments are useful to you.
Daniel Martinez Krahmer I have taken feed as 100 microns (0.1mm). Cutting speed is 120m/min.
I actually read a lot of literature on this & found out that we have to use an inclined mesh (inclination angle varying from 45 to 60deg) in order to get serrated chips. I dont know how to make this inclination.
Hello,
Do u consider the damage model in your FE model? Please try different fracture properties, like fracture energy and displacement, then you will get the serrated chips.
The serrated chips are mainly caused by the heat softening of the shear zone. The suggestions are as follows:
1) First check whether the cutting parameters are accurate, especially the cutting speed
2) Check the fracture characteristics, whether it is the fracture energy used or the damage displacement, this parameter needs to be adjusted according to the size of the grid
In general, 2D finite element serrated chips are very easy to come out, good luck
The following paper for your reference.
Zheng, Zhongpeng, Chenbing Ni, Yun Yang, Yuchao Bai, and Xin Jin. "Numerical Analysis of Serrated Chip Formation Mechanism with Johnson-Cook Parameters in Micro-Cutting of Ti6Al4V." Metals 11, no. 1 (2021): 102.
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