Numerical analysis of performance of different micro-grooved tools for cutting titanium alloy Ti-6Al-4V
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ORIGINAL ARTICLE
Numerical analysis of performance of different micro-grooved tools for cutting titanium alloy Ti-6Al-4V Xuchao Miao 1 & Xu Zhang 1 & Xin Liu 1 & Qianxi Yu 1 & Liqiang Zhang 1 Received: 25 February 2020 / Accepted: 22 September 2020 / Published online: 7 October 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract To achieve a better performance, a novel cutting tool has been developed with micro-grooves on its rake face. Such tools have great potential in manufacturing. However, micro-grooves of improper directions and shapes may adversely affect cutting tools. This paper investigates the performance of newly designed cemented carbide (WC/Co) cutting tools with micro-grooves on the rake face in the machining of titanium alloy Ti-6A1-4V using finite element (FEM) simulation. The objectives are to explore the influence of the directions and geometrical shapes of micro-grooves on the performance of cutting tools in dry turning of the titanium alloy and to compare it with conventional cutting tools. Specifically, the following aspects are compared: cutting temperature, cutting force, chip morphology, and stress distribution. It is found that these micro-grooved cutting tools generate lower cutting force and cutting temperature and increase chip curling. The maximum reduction of cutting force and cutting temperature occurs under different machining parameters. Compared with linear micro-grooves, the curvilinear micro-grooves diffuse the tool stress and weaken the stress concentration on cutting edges. In addition, the secondary cutting phenomenon of micro-grooved tools is analyzed, which can be effectively alleviated by reducing the width of micro-grooves and setting a reasonable radius of the secondary cutting edge. Keywords Micro-grooved tool . Dry cutting . Cutting performance . Ti-6Al-4V . Finite element method
1 Introduction Nowadays, main components and parts made from titanium alloys are extensively utilized in the aerospace industry owing to their superior structure and physical properties. However, because of its low thermal conductivity, high chemical reactivity, and low modulus of elasticity, titanium alloys are widely considered to be a typical difficult-to-machine material [1, 2]. Many researchers try different ways to alleviate this problem. Currently, some engineers have made remarkable achievements in improving the machinability of Ti-6Al-V4. In order to reduce the heat generated when processing titanium alloys, micro-lubrication and cryogenic cooling are widely used in machining titanium alloys. Compared with dry cutting, the
* Xu Zhang [email protected] 1
School of Mechanical and Automotive Engineering, Shanghai University of Engineering Science, Shanghai 201620, China
five kinds of lubro-cooling mechanisms have achieved good results in tool wear [3]. It is also a common way to process titanium alloy under the condition of minimum quantity lubrication, because the lubricant effectively penetrates the chip and the tool contact surface to reduce friction [4]. Howev
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