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Simulation of serrated chip formation in micro-milling of titanium alloy Ti-6Al-4V using 2D elasto-viscoplastic finite element modeling

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Abstract

Finite element simulations have been utilized in analyses of machining process for several decades. In mechanical micromachining, finite element simulation can also be used for predicting cutting forces, minimal chip thickness, temperatures, and tool wear. The accuracy of results and the computational cost are highly dependent upon the assumptions which govern that particular chip formation problem. This study presents a comparison of two different material assumptions in finite element simulation of micro-milling titanium alloy Ti-6Al-4V. The same simulation was conducted by using the elasto-viscoplastic and the viscoplastic material assumptions. The predicted results are compared against the experimental observations. The results have shown that the material assumption has a major effect on the mechanism of chip formation and heat generation but a minor effect on the cutting force and tool wear prediction. In terms of computational cost, it was found that the simulation with the viscoplastic material assumption can reduce simulation time up to eight times that of required for a simulation with elasto-viscoplastic assumption.

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Authors and Affiliations

  1. Department of Industrial Engineering, Faculty of Engineering, Burapha University, Chonburi, 20131, Thailand

    Thanongsak Thepsonthi

  2. Department of Industrial and Systems Engineering, Rutgers, The State University of New Jersey, 96 Frelinghuysen Road, Piscataway, NJ, 08554, USA

    Tuğrul Özel

Authors
  1. Thanongsak Thepsonthi
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  2. Tuğrul Özel
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Correspondence to Tuğrul Özel.

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Thepsonthi, T., Özel, T. Simulation of serrated chip formation in micro-milling of titanium alloy Ti-6Al-4V using 2D elasto-viscoplastic finite element modeling. Prod. Eng. Res. Devel. 10, 575–586 (2016). https://doi.org/10.1007/s11740-016-0701-8

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  • DOI: https://doi.org/10.1007/s11740-016-0701-8

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