Optimization of cutting forces on turning of Ti-6Al-4V Alloy by 3D FEM simulation analysis
Keywords:
Ti-6Al-4V, cutting force, turning, finite element method, optimization
Abstract
The turning process is widely used in the critical parts of machine tools used in the manufacturing industry, aerospace industry, and automobile and mold parts. However, the turning process is desired to obtain the lowest cutting force by variable cutting parameters. Therefore, estimation of optimum parameters and minimum cutting force is essential for Ti-6Al-4V, known as difficult-to-machine materials. This study aimed to investigate the impact of process parameters on the cutting force of Ti-6Al-4V alloy in turning operation by numerical analysis. Analyzes were performed at three levels of cutting speeds (55, 75, and 95 m/min), feed rates (0.12, 0.17, and 0.22 mm/rev), and depths of cut (1, 1.5, and 2 mm), respectively. Using Third Wave AdvantEdge software in finite element method (FEM), modeling and analysis of cutting forces. In addition, Signal/Noise (S/N) ratios were calculated to determine the optimum levels of cutting parameters, and Analysis of Variance (ANOVA) was used to determine the effects of cutting parameters on cutting force based on the outputs of numerical simulation results. As a result, FEM analysis and the results of similar studies in the literature overlap. The optimum cutting parameter was obtained in A1B1C1 in the results of the experimental and statistical analyzes. ANOVA results demonstrated that the depth of cut was the most significant parameter on the cutting force.
References
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[3] Carou, D., et al., Experimental study for the effective and sustainable repair and maintenance of bars made of Ti-6Al-4V alloy. Application to the aeronautic industry. Journal of Cleaner Production, 2017. 164: p. 465-475.
[4] Mia, M. and N.R. Dhar, Effects of duplex jets high-pressure coolant on machining temperature and machinability of Ti-6Al-4V superalloy. Journal of Materials Processing Technology, 2018. 252: p. 688-696.
[5] Vijayaraghavan, V., et al., A finite element based data analytics approach for modeling turning process of Inconel 718 alloys. Journal of cleaner production, 2016. 137: p. 1619-1627.
[6] Korkmaz, M.E. and M. Günay, Finite Element Modelling of Cutting Forces and Power Consumption in Turning of AISI 420 Martensitic Stainless Steel. Arabian Journal for Science & Engineering (Springer Science & Business Media BV), 2018. 43(9).
[7] Wang, F., et al., Three-dimensional finite element modeling of high-speed end milling operations of Ti-6Al-4V. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture, 2014. 228(6): p. 893-902.
[8] Wu, H. and S. Zhang, 3D FEM simulation of milling process for titanium alloy Ti6Al4V. The International Journal of Advanced Manufacturing Technology, 2014. 71(5-8): p. 1319-1326.
[9] Arrazola, P., et al. Finite element modeling of chip formation process with Abaqus/Explicit 6.3. in VII International Conference on Computational Plasticity, Barcelona. 2005.
[10] Han, R.D. and J. Wu. Finite element simulation of drilling based on third wave systems AdvantEdge. in Key Engineering Materials. 2010. Trans Tech Publ.
[11] Dali, M., J. Ghani, and C.C. Haron, Comparison between dynamic and non-dynamic cutting tool option in FEM simulation for producing dimple structure. Procedia CIRP, 2017. 58: p. 613-616.
[12] Uğur, L. and H. Kazan, Finite element modeling of power consumption in turning of AISI 1040 steel. Journal of Engineering Research and Applied Science, 2020. 9(2): p. 1597-1601.
[13] Parida, A.K. and K. Maity, Hot machining of Ti–6Al–4V: FE analysis and experimental validation. Sādhanā, 2019. 44(6): p. 1-6.
[14] Ugur, L., 3D end milling of AISI 1040 finite element thermal analysis. Journal of Engineering Research and Applied Science, 2019. 8(2): p. 1286-1290.
[15] Parida, A. and K. Maity. Finite element method and experimental investigation of hot turning of Inconel 718. in Advanced Engineering Forum. 2016. Trans Tech Publ.
[16] Aydın, K., et al., Experimental and Numerical Study of Cutting Force Performance of Wave Form End Mills on Gray Cast Iron. Arabian Journal for Science and Engineering, 2021. 46(12): p. 12299-12307.
[17] Zhang, Y., et al., FE-model for titanium alloy (Ti-6Al-4V) cutting based on the identification of limiting shear stress at tool-chip interface. International journal of material forming, 2011. 4(1): p. 11-23.
[18] Yuan, Y., et al., Modeling of cutting forces in micro end-milling. Journal of Manufacturing Processes, 2018. 31: p. 844-858.
[19] Pan, Z., et al., Prediction of machining-induced phase transformation and grain growth of Ti-6Al-4 V alloy. The International Journal of Advanced Manufacturing Technology, 2016. 87(1): p. 859-866.
[20] Shrot, A. and M. Bäker, Determination of Johnson–Cook parameters from machining simulations. Computational Materials Science, 2012. 52(1): p. 298-304.
[21] AdvantEdge 7.1 User’s Manual, Third Wave Systems, 2020.
[22] AKGÜN, M. and H. DEMİR, Optimization and finite element modelling of tool wear in milling of Inconel 625 superalloy. Politeknik Dergisi, 2021. 24(2): p. 391-400.
[23] Öztürk, B., L. Uğur, and A. Yildiz, Investigation of effect on energy consumption of surface roughness in X-axis and spindle servo motors in slot milling operation. Measurement, 2019. 139: p. 92-102.
[24] Özlü, B., Experimental and Statistical Investigation of the Effects of Cutting Parameters on Kerf Quality and Surface Roughness in Laser Cutting of al 5083 Alloy. Surface Review and Letters, 2021. 28(10): p. 2150093.
[25] Sandvik Coromant Tool Guide. 05.05.2021]; Available from: https://www.sandvik.coromant.com/tr-tr/products/pages/toolguide.aspx.
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[27] Demir, H. and S. Gündüz, The effects of aging on machinability of 6061 aluminium alloy. Materials & Design, 2009. 30(5): p. 1480-1483.
[28] Özlü, B., Sleipner soğuk iş takım çeliğinin tornalanmasında kesme parametrelerinin kesme kuvveti, yüzey pürüzlülüğü ve talaş şekli üzerine etkisinin incelenmesi. Journal of the Faculty of Engineering & Architecture of Gazi University, 2021. 36(3).
[29] Çiçek, A., et al., Performance of Multilayer Coated and Cryo-Treated Uncoated Tools in Machining of AISI H13 Tool Steel—Part 1: Tungsten Carbide End Mills. Journal of Materials Engineering and Performance, 2021: p. 1-10.
Published
2021-12-31
How to Cite
Ozlu, B., & Ugur, L. (2021). Optimization of cutting forces on turning of Ti-6Al-4V Alloy by 3D FEM simulation analysis. Journal of Engineering Research and Applied Science, 10(2), 1789-1795. Retrieved from http://www.journaleras.com/index.php/jeras/article/view/256
Section
Articles
