Finite Element Simulation For The Cutting Process Of Titanium Alloy And Superalloy

Titanium Alloy and Superalloy are typical hard-cutting materials, thecontents of which play a dominant role in the aircraft engine and structural body.And the most parts have complex and thin-walled shapes, also the characteristicsof high precision of dimension and high finish and large amount of metalremoval, it is the emphasis and difficulty to assure the high efficiency and thehigh precision and safety. So, it is significant to deeply study the cuttingmechanism of Titanium Alloy and Superalloy and optimize the cutting process.Based on the research results of this field at home and abroad, the paperuses the finite element simulation to further study the cutting processes ofTitanium Alloy Ti6Al4V and Superalloy GH4169by means of the combination oftheoretical analysis and experimental research.Firstly， the paper builds the two dimension orthogonal cutting finiteelement models of Titanium Alloy Ti6Al4V by setting reasonable material unitfailure model and using the grid adaptive control technology and studies thematerial deformation behavior in the formation process of chip adiabatic shearbehavior, the formation mechanism of cutting form and the variation law of thesawtooth chip. Then by the curve change characteristics between shear angle andcutting force, explain that the mutagenicity unthermoplastic shear force andperiodic fracture collectively cause the formation of sawtooth chip.Secondly, construct the three dimensional cutting finite element models ofTitanium Alloy and Superalloy, simulate and analyse the characteristics of chipshape, cutting temperature, cutting force and residual stress and use PCBN andPCD tools to carry out lots of single factor experiments of cutting force andcutting temperature towards Titanium Alloy Ti6Al4V and Superalloy GH4169.By experiment and simulation analysis comparison, get the change law of cuttingforce and cutting temperature with different cutting parameters, providing beneficial reference for optimization of the cutting technological parametersoptimization.Lastly, in order to study the change law of cutting force in the process ofhigh speed milling of Titanium Alloy Ti6Al4V, build milling model of Ball-endMill with finite element method and by comparison and analysis the test andsimulation results draw the following conclutions: high rotational speed,relatively large amount of feed, and cutting depth as few as possible are neededin the process of cutting.