损伤演化对Ti6Al4V高速切削仿真结果的影响
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摘要
利用ABAQUS有限元分析软件建立了Ti6Al4V二维切削仿真模型,在模型其他参数(本构参数、初始损伤参数等)固定不变时,得到了不同损伤演化特征参数(断裂能)取值下的切削力、切削温度和切屑形貌,以此来研究损伤演化过程对仿真结果的影响。研究发现随着断裂能取值的减小,仿真的切削力、切削温度会降低,切屑的锯齿化程度会变得严重。在切削速度为180m/min,进给量为0.1mm/r的条件下进行了Ti6Al4V正交切削实验,测量了切削力,将仿真得到的主切削力和切屑锯齿化程度与实验结果进行对比,确定了适合本研究建立的仿真模型的合理断裂能值。结果表明,在使用此断裂能取值时,仿真得到的切削力和切屑形态与实验值有很好的一致性。在消除了能量密度对仿真模型的影响后,进行了4组验证实验,仿真结果与验证实验的结果相吻合,证明了断裂能取值的准确性。
Based on the finite element analysis software ABAQUS,a two-dimensional cutting simulation model for Ti6Al4V is established.In order to investigate the effects of the damage evolution process on the simulation results,the cutting force,cutting temperature,and chip morphology under different damage evolution characteristic parameters(fracture energy)are obtained when the other model parameters(constitutive parameters,initial damage parameters,etc.)are fixed.The research finds that the simulated cutting force and the cutting temperature decrease with the decrease of value of the fracture energy.making the serrated degree of the chip severer.The orthogonal experiments of machining Ti6Al4V are carried out to measure the cutting force at the cutting speed of 180 m/min and feed rate of 0.1 mm/r.By comparing the simulated main cutting force and the serrated degree of the chip with the experimental results,the reasonable value of fracture energy suitable for the established simulation model is determined.The results show that the cutting force and the chip geometry obtained by simulations are in good agreement with the experimental values when the reasonable fracture energy value is used.After eliminating the effects of energy density on the simulation model,four sets of validation experiment are conducted.The simulated results are consistent with the experimental results of the verification experiments,and the accuracy of the fracture energy values is verified.
Based on the finite element analysis software ABAQUS,a two-dimensional cutting simulation model for Ti6Al4V is established.In order to investigate the effects of the damage evolution process on the simulation results,the cutting force,cutting temperature,and chip morphology under different damage evolution characteristic parameters(fracture energy)are obtained when the other model parameters(constitutive parameters,initial damage parameters,etc.)are fixed.The research finds that the simulated cutting force and the cutting temperature decrease with the decrease of value of the fracture energy.making the serrated degree of the chip severer.The orthogonal experiments of machining Ti6Al4V are carried out to measure the cutting force at the cutting speed of 180 m/min and feed rate of 0.1 mm/r.By comparing the simulated main cutting force and the serrated degree of the chip with the experimental results,the reasonable value of fracture energy suitable for the established simulation model is determined.The results show that the cutting force and the chip geometry obtained by simulations are in good agreement with the experimental values when the reasonable fracture energy value is used.After eliminating the effects of energy density on the simulation model,four sets of validation experiment are conducted.The simulated results are consistent with the experimental results of the verification experiments,and the accuracy of the fracture energy values is verified.
引文
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[18]ZOREV N N.Inter-relationship between shear processes occurring along tool face and shear plane in metal cutting[J].International Research in Production Engineering,1963,49:143-152.
[19]BUDAK E,OZLU E.Development of a thermomechanical cutting process model for machining process simulations[J].CIRP Annals-Manufacturing Technology,2008,57(1):97-100.
[20]UMBRELLO D.Finite element simulation of conventional and high speed machining of Ti6Al4Valloy[J].Journal of Materials Processing Technology,2008,196(1-3):79-87.
[21]RECH J,ARRAZOLA P J,CLAUDIN C,et al.Characterisation of friction and heat partition coefficients at the tool-work material interface in cutting[J].CIRP AnnalsManufacturing Technology,2013,62(1):79-82.
[22]BAI W,SUN R L,ROY A,et al.Improved analytical prediction of chip formation in orthogonal cutting of titanium alloy Ti6Al4V[J].International Journal of Mechanical Sciences,2017,133:357-367.
[23]SIMA M,OZEL T.Modified material constitutive models for serrated chip formation simulations and experimental validation in machining of titanium alloy Ti-6Al-4V[J].International Journal of Machine Tools and Manufacture,2010,50(11):943-960.
[24]JOHNSON G R,COOK W H.Fracture characteristics of three metals subjected to various strains,strain rates,temperatures and pressures[J].Engineering Fracture Mechanics,1985,21(1):31-48.
[25]HILLERBORG A,MODEER M,PETERSSON P E.Analysis of crack formation and crack growth in concrete by means of fracture mechanics and finite elements[J].Cement and Concrete Research,1976,6(6):773-781.
[26]SCHULZ H,ABELE E,SAHM A.Material aspects of chip formation in HSC machining[J].CIRP Annals-Manufacturing Technology,2001,50(1):45-48.
[27]MABROUKI T,GIRARDIN F,ASAD M,et al.Numerical and experimental study of dry cutting for an aeronautic aluminium alloy(A2024-T351)[J].International Journal of Machine Tools and Manufacture,2008,48(11):1187-1197.
[28]AMBATI R,YUAN H.FEM mesh-dependence in cutting process simulations[J].The International Journal of Advanced Manufacturing Technology,2011,53(1-4):313-323.
[29]ZHANG Y C,MABROUKI T,NELIAS D,et al.FE-model for titanium alloy(Ti-6Al-4V)cutting based on the identification of limiting shear stress at tool-chip interface[J].International Journal of Material Forming,2011,4(1):11-23.
[30]ZHANG Y C,MABROUKI T,NELIAS D,et al.Chip formation in orthogonal cutting considering interface limiting shear stress and damage evolution based on fracture energy approach[J].Finite Elements in Analysis and Design,2011,47(7):850-863.
[31]CHEN G,REN C Z,ZHANG P,et al.Measurement and finite element simulation of micro-cutting temperatures of tool tip and workpiece[J].International Journal of Machine Tools and Manufacture,2013,75:16-26.
[32]Titanium Ti-6Al-4V(Grade 5),Annealed[EB/OL].[2018-03-15].http:∥matweb.com/search/DataSheet.aspx?MatGUID=a0655d261898456b958e5f825ae8539-0&ckck=1.
[2]UMBRELLO D,M’SAOUBI R,OUTEIRO J C.The influence of Johnson-Cook material constants on finite element simulation of machining of AISI 316Lsteel[J].International Journal of Machine Tools and Manufacture,2007,47(3-4):462-470.
[3]刘战强,张克国.JC本构参数对绝热剪切影响的敏感性分析[J].航空学报,2011,32(11):2140-2146.LIU Z Q,ZHANG K G.Sensitivity analysis of JohnsonCook material constants on adiabatic shear[J].Acta Aeronautica et Astronautica Sinica,2011,32(11):2140-2146(in Chinese).
[4]SCHULZE V,ZANGER F.Numerical analysis of the influence of Johnson-Cook material parameters on the surface integrity of Ti-6Al-4V[J].Procedia Engineering,2011,19:306-311.
[5]DUCOBU F,RIVIERE-LORPHEVRE E,FILIPPI E.Material constitutive model and chip separation criterion influence on the modeling of Ti6Al4V machining with experimental validation in strictly orthogonal cutting condition[J].International Journal of Mechanical Sciences,2016,107:136-149.
[6]WANG B,LIU Z Q.Investigations on the chip formation mechanism and shear localization sensitivity of high-speed machining Ti6Al4V[J].The International Journal of Advanced Manufacturing Technology,2014,75(5-8):1065-1076.
[7]WANG B,LIU Z Q.Shear localization sensitivity analysis for Johnson-Cook constitutive parameters on serrated chips in high speed machining of Ti6Al4V[J].Simulation Modelling Practice and Theory,2015,55:63-76.
[8]《中国航空材料手册》编辑委员会.中国航空材料手册第4卷:钛合金,铜合金[M].第2版.北京:中国标准出版社,2001:107-126.Editorial Committee of China Aeronautical Materials Handbook.China aeronautical materials handbook Vol.4:Titanium alloy,copper alloy[M].2nd ed.Beijing:Stand Press China,2001:107-126(in Chinese).
[9]JOHNSON G R.A constitutive model and data for materials subjected to large strains,high strain rates,and high temperatures[C]∥Proceeding of the seventh international symposium on ballistics.Hague,Netherlands,1983:541-547.
[10]LEE W S,LIN C F.High-temperature deformation behaviour of Ti6Al4V alloy evaluated by high strain-rate compression tests[J].Journal of Materials Processing Technology,1998,75(1-3):127-136.
[11]LEE W S,LIN C F.Plastic deformation and fracture behaviour of Ti-6Al-4Valloy loaded with high strain rate under various temperatures[J].Materials Science and Engineering:A,1998,241(1-2):48-59.
[12]MEYER JR H W,KLEPONIS D S.Modeling the high strain rate behavior of titanium undergoing ballistic impact and penetration[J].International Journal of Impact Engineering,2001,26(1-10):509-521.
[13]CHEN G,REN C Z,YANG X Y,et al.Finite element simulation of high-speed machining of titanium alloy(Ti-6Al-4V)based on ductile failure model[J].The International Journal of Advanced Manufacturing Technology,2011,56(9-12):1027-1038.
[14]LI L,HE N.A FEA study on mechanisms of saw-tooth chip deformation in high speed cutting of Ti-6-Al-4Valloy[C]∥Fifth international conference on high speed machining(HSM).Metz,France,2006:14-16.
[15]LESUER D.Experimental investigation of material models for Ti-6Al-4V and 2024-T3:DOT/FAA/AR-00/25[R].Livermore:Lawrence Livermore National Laboratory,1999.
[16]ZHANG Y C,OUTEIRO J C,MABROUKI T.On the selection of Johnson-Cook constitutive model parameters for Ti-6Al-4Vusing three types of numerical models of orthogonal cutting[J].Procedia CIRP,2015,31:112-117.
[17]CHEN G,REN C Z,YU W,et al.Application of genetic algorithms for optimizing the Johnson-Cook constitutive model parameters when simulating the titanium alloy Ti-6Al-4V machining process[J].Proceedings of the Institution of Mechanical Engineers,Part B:Journal of Engineering Manufacture,2012,226(8):1287-1297.
[18]ZOREV N N.Inter-relationship between shear processes occurring along tool face and shear plane in metal cutting[J].International Research in Production Engineering,1963,49:143-152.
[19]BUDAK E,OZLU E.Development of a thermomechanical cutting process model for machining process simulations[J].CIRP Annals-Manufacturing Technology,2008,57(1):97-100.
[20]UMBRELLO D.Finite element simulation of conventional and high speed machining of Ti6Al4Valloy[J].Journal of Materials Processing Technology,2008,196(1-3):79-87.
[21]RECH J,ARRAZOLA P J,CLAUDIN C,et al.Characterisation of friction and heat partition coefficients at the tool-work material interface in cutting[J].CIRP AnnalsManufacturing Technology,2013,62(1):79-82.
[22]BAI W,SUN R L,ROY A,et al.Improved analytical prediction of chip formation in orthogonal cutting of titanium alloy Ti6Al4V[J].International Journal of Mechanical Sciences,2017,133:357-367.
[23]SIMA M,OZEL T.Modified material constitutive models for serrated chip formation simulations and experimental validation in machining of titanium alloy Ti-6Al-4V[J].International Journal of Machine Tools and Manufacture,2010,50(11):943-960.
[24]JOHNSON G R,COOK W H.Fracture characteristics of three metals subjected to various strains,strain rates,temperatures and pressures[J].Engineering Fracture Mechanics,1985,21(1):31-48.
[25]HILLERBORG A,MODEER M,PETERSSON P E.Analysis of crack formation and crack growth in concrete by means of fracture mechanics and finite elements[J].Cement and Concrete Research,1976,6(6):773-781.
[26]SCHULZ H,ABELE E,SAHM A.Material aspects of chip formation in HSC machining[J].CIRP Annals-Manufacturing Technology,2001,50(1):45-48.
[27]MABROUKI T,GIRARDIN F,ASAD M,et al.Numerical and experimental study of dry cutting for an aeronautic aluminium alloy(A2024-T351)[J].International Journal of Machine Tools and Manufacture,2008,48(11):1187-1197.
[28]AMBATI R,YUAN H.FEM mesh-dependence in cutting process simulations[J].The International Journal of Advanced Manufacturing Technology,2011,53(1-4):313-323.
[29]ZHANG Y C,MABROUKI T,NELIAS D,et al.FE-model for titanium alloy(Ti-6Al-4V)cutting based on the identification of limiting shear stress at tool-chip interface[J].International Journal of Material Forming,2011,4(1):11-23.
[30]ZHANG Y C,MABROUKI T,NELIAS D,et al.Chip formation in orthogonal cutting considering interface limiting shear stress and damage evolution based on fracture energy approach[J].Finite Elements in Analysis and Design,2011,47(7):850-863.
[31]CHEN G,REN C Z,ZHANG P,et al.Measurement and finite element simulation of micro-cutting temperatures of tool tip and workpiece[J].International Journal of Machine Tools and Manufacture,2013,75:16-26.
[32]Titanium Ti-6Al-4V(Grade 5),Annealed[EB/OL].[2018-03-15].http:∥matweb.com/search/DataSheet.aspx?MatGUID=a0655d261898456b958e5f825ae8539-0&ckck=1.