Finite Element Simulation Of Chip Formation In High Speed Cutting Of Ti6Al4V Alloy

High speed cutting (HSC) of titanium alloys is always one of the very complicated and urgent problems in aircraft, spacecraft and other manufacturing industries. This dissertation focuses on the chip formation process during high speed cutting Ti6Al4V alloys. Theoretical analysis, numerical simulation and experimental verification are applied in this research. The major research works are included as follows:1.The flow stress behavior of Ti6Al4V at the high temperature and strain-rate was investigated by means of split Hopkinson pressure bar (SHPB) test system. The Johnson-Cook (JC) model could be extraordinarily suitable for description of constitutive model in simulation of HSC. The obtained JC model from experimental results could accurately predict the flow stress.2.To simulate high speed orthogonal cutting of Ti6Al4V, a commercial FE code (ABAQUS/Explicit) has been used. This code adopt JC material model and shear failure criterion. Base on the finite element analysis, the mechanism of saw-tooth chip formation were disclosed. Effect of cutting speed, depth of cut and rake angles on cutting force, temperature, strains and saw-tooth chip formation was studied, which closely matched with that proposed in the literature.3.Through experiments of orthogonal cutting Ti6Al4V, cutting force, cutting temperature and chip morphology of the simulation are compared with the experimental data and were found to be in close agreement.