Multi-Physics Analysis of Machining Ti-6Al-4V Alloy: Experimental Characterization and a New Material Behavior Modeling
Abstract
:1. Introduction
2. Mechanisms of Machining Ti-6Al-4V
2.1. Experimental Tests
2.2. Analysis of the Cutting Process
2.2.1. Qualitative vs. Quantitative Analysis of Chips
2.2.2. Microstructural Analysis of Chips
3. Multi-Physics Modelling of the Ti-6Al-4V Behavior in Machining
3.1. Microstructure Dependent Flow Stress Model
3.2. Microstructure Dependent Damage Model
3.3. Application of the Coupled Microstructure-Damage Model
3.4. Grain Size Evolution
4. Application for Machining Simulations
4.1. Chip Morphology
4.2. Microstructure Evolution in the Chip
4.2.1. Grain Size Evolution
4.2.2. Link with Chip Segmentation
5. Conclusions
- The characterization of chips morphology shows a classical result for refractory alloys, such as Ti-6Al-4V: increasing feed and cutting speed intensify chip segmentation;
- The microstructure analysis of the ASB revealed the grains refinement and its interaction with damage;
- The proposed physical behavior model of Ti-6Al-4V considers this interaction. The simulated uniaxial tension showed how combined temperature/strain rate affects damage and DRX and, in turn, the stress/strain response (flow stress);
- The application of the material behavior model for FE simulation of machining Ti-6Al-4V showed the transition between unstable (aperiodic) and stable chip segmentation (periodic);
- In the ASB, giving rise to the chip segmentation, the DRX and damage were predicted, with fracture occurring from the chip-free surface propagating along with the ASB, while the DRX occurs in the ASB from the tool–chip interface;
- Finally, the material behavior model, implemented for FE simulation of machining, gives more insight into the mechanism of chip formation, particularly the interaction between DRX and damage. However, including a FE re-meshing of the cutting zone allows better results by correctly capturing the action at the tool tip and therefore what happens at the generated surface.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
Nomenclature
Basic parameters | |
Young modulus | |
Material density | |
Thermal expansion | |
Thermal conductivity | |
Specific Heat | |
Variables | |
Equivalent plastic strain | |
Equivalent plastic strain rate | |
Temperature | |
von Mises stress | |
damage variable | |
JC parameters | |
Initial yield stress | |
Hardening modulus | |
Strain rate dependency | |
Thermal softening | |
Strain hardening | |
Reference Temperature | |
Melting Temperature | |
Damage parameters | |
, , , , | Johnson–Cook damage initiation |
Damage initiation criteria | |
Fracture energy | |
Plastic displacement at damage initiation | |
Plastic displacement at fracture | |
JMAK model parameters | |
Recrystallized volume fraction | |
Dynamic recrystallization activation energy | |
Boltzmann constant | |
Critical equivalent plastic strain | |
, , , , | Critical strain |
, , , , | Recrystallized volume fraction |
, , , , | Grain size |
TANH model parameters | |
, , , | TANH model |
Contact/friction parameters | |
Sliding stress | |
Normal stress | |
Coefficient of friction | |
Sliding velocity | |
Heat transfer coefficient | |
Heat partition coefficient | |
Friction heat ratio | |
Friction heat | |
Friction heat to the tool | |
Friction heat to the work material | |
Interface work material temperature | |
Interface tool temperature | |
Cutting parameters | |
, | Cutting speed and feed |
Chip geometrical parameters | |
, | Max. and min. chip thickness |
Chip surface length | |
Chip segments peak to peak distance | |
Chip compression ratio | |
Segmentation ratio maximal value |
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Al | V | C | Fe | H | W | O | Ti |
---|---|---|---|---|---|---|---|
6% | 4% | ≤0.08% | ≤0.3 | ≤0.0125 | ≤0.07 | ≤0.2 | Balance |
Test N° | (mm/rev) | |
---|---|---|
1 | 25 | 0.075 |
2 | 100 | |
3 | 150 | |
4 | 25 | 0.18 |
5 | 100 | |
6 | 150 | |
7 | 25 | 0.35 |
8 | 100 | |
9 | 150 |
Average Value (μm) | Standard Deviation (μm) | Maximum Value (μm) | Minimum Value (μm) | Number of Indexed Grains | |
---|---|---|---|---|---|
Alpha phase | 3.13 | 2.2 | 14.2 | 0.2 | 686 |
Beta phase | 0.6 | 0.4 | 3.1 | 0.2 | 211 |
Mean Value (μm) | Standard Deviation (μm) | Max. Value (μm) | Min. Value (μm) | Number of Studied Grains (μm) | |
---|---|---|---|---|---|
Alpha phase | 0.37 | 0.31 | 3.36 | 0.22 | 663 |
(J·K−1·mol−1) | ||||||
---|---|---|---|---|---|---|
0.8 | 0 | 0.01 | 0.4 | 218 | 8.31 | 3 |
0.022 | 0 | 0.03 | 2 | 2 |
A (MPa) | B (MPa) | C | m | n | T0 (K°) | (s−1) | a | b | c | d |
---|---|---|---|---|---|---|---|---|---|---|
968 | 380 | 0.02 | 0.577 | 0.421 | 298 | 1 | 1.6 | 0.4 | 6 | 0.5 |
d1 | d2 | d3 | d4 | d5 |
---|---|---|---|---|
−0.09 | 0.25 | −0.5 | 0.014 | 3.87 |
a8 | n8 | m8 | d0 (μm) |
---|---|---|---|
3 | 0 | −0.03 | 3 |
E (GPa) | λ (W/mK) | α (K−1) | CP (J/kgK) | ρ (kg/m3) | |
---|---|---|---|---|---|
Ti-6Al-4V | 113.8 | 7.3 | 8.6 × 10−6 | 580 | 4430 |
WC–Co | 800 | 46 | 4.7 × 10−6 | 203 | 15,000 |
COF | τlim (MPa) | ht (mW/mm2 °C) | ||
---|---|---|---|---|
0.6 | no limit | 1 | 0.5 | 2000 |
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Haddag, B.; Yameogo, D.; Nouari, M.; Makich, H. Multi-Physics Analysis of Machining Ti-6Al-4V Alloy: Experimental Characterization and a New Material Behavior Modeling. Metals 2022, 12, 581. https://doi.org/10.3390/met12040581
Haddag B, Yameogo D, Nouari M, Makich H. Multi-Physics Analysis of Machining Ti-6Al-4V Alloy: Experimental Characterization and a New Material Behavior Modeling. Metals. 2022; 12(4):581. https://doi.org/10.3390/met12040581
Chicago/Turabian StyleHaddag, Badis, Dominique Yameogo, Mohammed Nouari, and Hamid Makich. 2022. "Multi-Physics Analysis of Machining Ti-6Al-4V Alloy: Experimental Characterization and a New Material Behavior Modeling" Metals 12, no. 4: 581. https://doi.org/10.3390/met12040581