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5 International & 26 All India Manufacturing Technology, Design and Research Conference (AIMTDR 2014) December 12 –14 , 2014,
IIT Guwahati, Assam, India

Finite Element Modeling for Prediction of Cutting Forces during Micro


Turning of Titanium Alloy
1 2*
Jagadesh T , Samuel G L
1
Department of Mechanical Engineering, Indian Institute of Technology
Madras, Chennai, India, 600036,
1 2
E-Mail: jagadeshvel@gmail.com, Email: samuelgl@iitm.ac.in

Abstract
Micromachining of industrial products, is playing an important role in manufacturing of axi-symmetricminiaturized
parts especially in biomedical and aerospace applications.This paper presents the development of 3D oblique finite
element modeling for prediction of cutting forces, thrust force, feed force, and tool chip interface temperatureduring
micro turning process. Titanium alloy (Ti6Al4V) and Coated carbide tool (TiN/AlTiN) is considered as work and
tool material respectively.Johnson- Cook material model with strain gradient plasticity is used to represent the flow
stress of the work material. When uncut chip thickness is equal to or less than the edge radius, thrust force is
dominant over the cutting force due to rubbing and ploughing action. When cutting speed increases there is decrease
in cutting force due to thermal softening effect. When depth of cut and uncutchip thickness is less than edge radius
there is increase in specific cutting energy due to material strengthening effects. Tool chip interface temperature
increases by increasing the cutting speed.Simulated cutting force values are agree well with the experiment values.
Key words: FEM, Cutting forces, edge radius.

1. Introduction cBNcoated tool. Rao and


shunmugam(2012)developedanalytical model for the
Titanium alloyshave been widely used in prediction offorces in micro end milling process with
biomedical products due to superior properties such as consideration of edge radius and material strengthening
biocompatibility, high strength to weight ratio, and effects.Liu and melkote (2004)investigated material
corrosion resistance. Machining of titanium alloy is strengthening mechanisms and suggested that decrease
difficult due to low thermal conductivity, low elastic in secondary deformation zone temperature, and strain
modulus and high chemical reactivity with tool material gradient are the reason for material strengthening.
Yangand Liu (1999).Several researches have tried with Several researches investigated on Finite
different coated tools to minimize the tool wear and for element model (FEM) for macromachining of titanium
improving the accuracy of the componentOzelet al. alloy. Umbrello (2008)studied finite element simulation
(2010),Jaffery and Mativenga (2012). In the present of titanium alloy (Ti6Al4V) using three different John
paper, coated carbide insert (TiN/AlTiN) is being used Cook constitutive model parameters. Results suggested
as a tool to machine titanium alloy (Ti6Al4V). The that Lee and Lin (1998) parameters shows good
advantage of such coating is to reduce the friction and agreement of cutting force and chip morphology
adhesion between chip and cutting tool. In addition to withexperiments during conventional and high speed
that AlTiN has good oxidation resistance, wear machining.Sima and Ozel (2010)investigated strain
resistanceand high chemical stability at high softening, temperature dependent flow softening, and
temperatures due to the formation of Al2O3 film. flow softening at high strain values in modified John
The mechanism of material removal in Cook constitutive model. Results suggested that flow
micromachining is different from macro machining due softening at high strain values predicted accurately with
to size effect.Finite element model is used to predict the experiment values.Karpat (2011) analyzed temperature
cutting forces, tool wear in advance to eliminate dependent flow softening of Ti6Al4V using 2D FEM.
problem during actual machining process that leads Results suggested that flow softening occurs at 350 ° C
toreduce the experimentation cost.Woonet al. (2008) that is below the recrystallization temperature. Ti6Al4V
developed finite element model to predict the influence with different initial microstructures are needed to
of tool edge radius on tool chip contact length address this problem. Shao et al.(2010) developed finite
andcontact force.Ozelet al. (2011) investigated FEM for element model for prediction of cutting temperature and
prediction of forces, temperature and wear rate during tool wear depth considering thermodynamically
micro milling of titanium alloy with carbide and constitutive equation. Ozel (2009) investigated

414-1
influence of micro edge n as rigid and workpiece is
geometry (chamfer i considered as
insert, uniform hone t viscoplastic material. To
insert, variable hone e get the influence of edge
insert, waterfall hone radius a fine mesh
insert) on forces, stress, e density is given at the tip
friction and tool wear in l of the tool is shown in
PcBN tool. Results
95figure
e
suggested that variable m 2. The edge radius of
micro geometry insert e the cutting insert is 15
has reduced tool wear, n µ m is shown in figure 6.
heat generation and less t
plastic strain.
m Figure 1
Most of the
o Oblique
work done in the
d cutting
literature study
e
is
l
2D and 3D orthogonal Figure 1 shows the
FEM for macro There are three oblique cutting where
machining. To get the formulations used in the cutting edge is inclined at
actual cutting process, finite element model of 95° to the feed velocity.
3D oblique finite element machining process: Tool is considered Fine mesh
model has been Lagrangian, Eulerian, or 0.2mm nose
developed in the present Arbitrary
investigation. Thereare radius
LagrangianEulerian.
very few investigations Figure 2 Geometry of
Material being removed insert with finite
made so far on from the workpiece is element mesh
simulation of micro exposed to severe plastic
turning of Titanium deformation and it causes
alloy. This paper is distortion of elements Minimum element size of
essential to understand during FEM simulation. the workpiece is
the mechanism of Therefore mesh 0.002mm given in all
material removal at the regeneration in the simulation conditions.
micro scale. workpiece is needed. In The shape of the
addition this chip element is four node
2 separation criteria must tetrahedron element.
. be provided in Eulerian Figure 3 shows the
approach. To overcome simplified model of
this problem, in this workpiece fixed at
M bottom portion in
paper finite element
e X,Y,and Z directions.In
simulation has been
t carried out by implicit the present study uncut
h Lagrangian method in chip thickness is assumed
o which the chip is formed to be 10, 15, 20 microns.
by continuous remeshing Figure 4 shows coating
d of AlTiN and TiN over
using DEFORM 3D
o carbide tool.
software. Ozelet al.
l (2011) studied the FEM
o of machining of inconel
g 718 by using two
y different FE software.
Results suggested that
2 predicted cutting forces,
. cutting temperature,
1 strain, and stress values
are almost similar in both
F DEFORM 3D and Figure3
i ABAQUS/Explicit. Workpiece
fixed at
bottom
portion

F
ig
u
r
e
4
C
o
a
te
d
c
a
r
b
i
d
e
i
n
s
e
rt
2.2 Material modeling Shear friction law and colulomb friction law are used to
 ∈&   −
m represent the friction between tool and chip interface.
T To
σ = ( A + B ∈n )  1 +  1 −    τ
C ln
 ∈& 0  Tm − To  m= (2)
 
 
µ
1/ 2
k




 where,m = shear friction factor.
  (1) τ = frictional shear stress.

  

  18a 2 b G 2
1 
+
   m  2 k = work material flow stress.
 
 ∈ &  − 
T T  
  
 L  ( A + B ∈ )  1 + C ln
n
 1 − 
o
 A constant shear friction factor m = 0.95 is used in all
  
∈& 0   Tm − To   
 
 
 
    simulation conditions Ozelet al. (2010).Table 1 shows
  the thermo mechanical properties of tool and workpiece
material. The formula for calculating shear frictor is
shown in Equation 2, and specific cutting energy is
where (A) yield strength of the material, (B) strain shown in Equation 3.
hardening modulus, (C) strain rate sensitivity
coefficient, ( ) plastic strain, ( ) strain rate, ( ) Cutting tool
reference plastic strain rate, (T) Workpiece temperature,
(Tm)Melting temperature, (To) Room temperature, (m) Edge
thermal softening coefficient, (n) Hardening coefficient, radius
(G) shear modulus, (L) characteristic length in strain
gradient plasticity model, (b) magnitude of burger Saw tooth
vector, (a) constant. The optimized material constant for chip
John and cook model are; A = 782.7MPa, B = 498.MPa, formation
C = 0.028, m= 1, n = 0.28, To= 20°C, Tm= 1660°C.
Modified Johnson–Cook material model with strain
Workpiece
gradient plasticity is used to represent the flow stress of
the work material as shown in Equation 1 Shen and
Ding (2013). Figure 6 Finite element model

Fc × V c
Specific cutting energy =
DOC ×Vc × f
(3)

Fc = Cutting force, N
Vc = Cutting speed, m/min
DOC= Depth of cut, µ
mf = feed, µ m/rev

during oblique finite element cutting model. The reason


for the saw tooth chip formation in machining of
titanium alloy is due to adiabatic shear sensitivity Wan
etProperty
al.(2012). Ti6Al4V WC- AlTi TiN
Co N
5 3 3
Figure 5 Variation of flow stress with strain at 2.3 Friction modeling
Youngs (0.7412* 5.e 560e 251e
various temperatures modulus, T)+113375
Mpa
0.0011*
Thermal 7.039e 0.042 0.008 0.008*
Figure 5 shows the variation of flow stress with strain conductivi T
*T+ 1*T T+
at various temperatures. Figure 6 shows the 3D oblique ty 36 +11.9 19.8
model of tool and workpiece along with the chip formed Wm °C
-1 -1
5
-9 -6 -6 -6
Thermal 3.10 *T+ 4.7e 9.4e 9.4e
-6
expansion 7.10
-
mm mm
1° -1
C
Table 1.Mechanical and thermal properties of tool
and work material.
than edge radius, cutting force is dominant over thrust
force due to shearing action is shown in the figure. 9.

3.2 Effect of cutting forces on cutting speed


0.0007*T
Heat 2.24e 0.000 0.000 3
capacity 5*T 3*T
-2 -1
Nmm C +2.07 +0.57
Poisson's 0.342 0.25 0.25 0.25
ratio
results that, when the When cutting
Yen et al.(2004), cutting edge radius is speed increases, from
Ozelet al. equal to or less than the 19m/min to 37m/min
(2010),Jaffery and there is sudden decrease
M in cutting force due to
a increase of temperature
t in the cutting zone. with
i further increase of
v cutting speed there is
e gradual decrease of
n cutting force due to
g thermal softening effect.
a When cutting speed
increases from
( 57m/min to
2 75m/min the value of
0 cutting force and Figure 10
1 Variation of forces
2 with time at
) Figure 7 Variation 57m/min,
. of forces with 20µm/rev,
time at 30µm
3 19m/min, 10µm/rev, depth of
. 10µm depth of cut. cut.

R
e
s
u
l
t
s

a Figure 9
n Variation of
d forces with time
at
19m/min,
d
20µm/rev,
i
10µm
s
depth of
c Figure 8 Variation cut.
u of forces with
s time at
s 19m/min, 15µm/rev, thrust force coming
i 10µm depth of cut. close, and indicates
o that it is not favorable
n condition for
uncutchip thickness machining. There is
3.1
thurst force is more than no much variation in
Effe
the cutting force due to axial force when
ct of
rubbing and ploughing cutting speed
force
action is shown in the increases from
s on
figure 7 and 8. When 19m/min to 75m/min.
edge
uncut chip thickness is Figure 10 shows the
radi
greater variation of forces
us
with time at 57m/min,
It is observed 20 µ m/rev, and 30µ m
from the simulation depth of cut.
3.3 Effect of cutting forces on feed rate and depth and hence there is increase of tool chip temperature
of cut. by increasing the cutting speed.

Figure 11 shows the variation of cutting force with 3.5 Finite element model validation
feed rate at 19m/min. Cutting force increases with
increase of feed rate and depth of cut due to Micro turning of Ti6Al4V have been carried
increased volume of material removal. out using coated carbide tool (AlTiN/TiN) in micro
turning setup at IIT Madras. Experiments were
conducted by varying cutting speed, feed and depth
of cut. Simulated force values are compared with
experimental values.

Figure 11 Variation of cutting force with feed


rate at 19m/min.

3.4 Specific cutting energy Figure 13 Variation of tool chip temperature with
cutting speed at 20 µm/rev,30µm depth of cut.

Figure 12 Variation of specific cutting energy at


19m/min.
Figure 14 Comparison of experimental and
simulated cutting force at 19m/min, 20µm/rev,
Figure 12 shows the variation of specific cutting 10µm depth of cut.
energy at various feed rates. When uncutchip
thickness is less than the edge radius there is
increase in specific cutting energy due to strain Figure 14 shows comparison of experimental and
gradient induced material strengthening effectsLiu simulated cutting forces with time. Figure 15 shows the
and melkote (2004). Figure 13 shows the variation of comparison of experimental and simulated cutting
tool chip interface temperature with cutting speed. forces at 19m/min and 30µ m depth of cut.
Since titanium alloy have low thermal conductivity,
heat generated during machining are not dissipated,
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