Finite Element Simulation Research Of Tool Wear And Life Prediction In Titanium Alloy Ti6Al4V Side Milling Process

Titanium alloy(Ti6Al4V),as a common material in the aerospace field,has many characteristics that are compatible with the requirements of the aerospace industry,such as small density,high strength,high temperature resistance and corrosion resistance.The milling is a common method in the processing of titanium alloys.However,the low thermal conductivity and low elasticity modulus of titanium alloys make the cutting force and cutting heat increase,which leads to a further increase in cutting temperature and aggravates tool wear.For the above reasons,titanium alloys are generally regarded as a difficult-to-process material.Therefore,the main research contents of this paper are as follows:Firstly,a friction coefficient model between the tool and workpiece is established in milling titanium alloy.This friction model mainly considers the influence of contact stress and temperature on the friction coefficient.The ball-disk friction test data is used to fit and verify the accuracy of the friction coefficient model.Then,based on the oblique angle cutting theory,a milling force model with variable friction coefficient is constructed.By comparing with the milling force obtained from the experiment,the error value of the prediction model is calculated and the reason is analyzed.Secondly,the ABAQUS simulation software is used to realize the simulation that the cemented carbide end mills milling titanium alloy,and the simulation results of Mises stress cloud diagram,tool temperature cloud diagram and milling force curve are obtained.Compared with experimental milling force,the source of the error can be found to obtain the accuracy of the established model,which lays the foundation for tool wear simulation research.Thirdly,based on the finite element simulation of milling processing by ABAQUS,the Python is used for secondary development to obtain the tool wear value during the milling process.The finite element simulation results are compared with experimental results to verify the accuracy of the ABAQUS tool wear simulation model.Finally,based on the finite element simulation results,the influence of different cutting parameters on the cutting force and cutting temperature during the side milling process of titanium alloy is studied.Based on the finite element simulation of tool wear,the tool life prediction model is established,and the model is verified by experiments.The established tool life prediction model can provide guiding suggestions for actual machining.This paper starts with the study of tool flank wear in milling Ti6Al4 V,a friction coefficient model between the tool and workpiece considering stress and temperature is established,and a finite element simulation model for tool wear during milling is finished at the same time.the tool life prediction model is established based on tool wear finite element simulation,which can provide theoretical support for the actual titanium alloy processing process.