Finite Element Investigation on Cutting Force and Residual Stress in 3D Elliptical Vibration Cutting Ti6Al4V

• Published in: Micromachines (Basel) Vol. 13; no. 8; p. 1278
• Main Authors: Li, Shiyu, Han, Jinguo, Yu, Haiqiang, Wang, Jinhui, Lu, Mingming, Tian, Yebing, Lin, Jieqiong
• Format: Journal Article
• Language: English
• Published: Basel MDPI AG 08.08.2022; MDPI
• Subjects: 3D EVC; Amplitudes; Analysis; Composite materials; Compressive properties; Constitutive models; Cutting force; Cutting parameters; Cutting speed; Cutting wear; Efficiency; Experimental methods; Finite element analysis; Finite element method; Hardness; Investigations; Kinematics; Machinability; Machine tools; Machining; Mechanical properties; Medical research; Modulus of elasticity; Research methodology; Residual stress; Simulation; Strain hardening; Ti-6Al-4V alloy; Titanium alloys; Titanium base alloys; Tool wear; Vibration analysis; Workpieces
• ISSN: 2072-666X; 2072-666X
• DOI: 10.3390/mi13081278

Titanium alloy is a typical difficult-to-machine material with features of superhigh strength and hardness, and low elastic modulus. It is difficult to guarantee the processing quality and efficiency due to the high cutting force and tool wear in conventional cutting. Elliptical vibration cutting (EVC) as an effective method can improve the machinability of titanium alloys. In this paper, the finite element method (FEM) was adopted to study the cutting force and residual stress of 3D EVC in machining of Ti6Al4V. The Johnson-Cook constitutive model was utilized to illustrate the plastic behavior of Ti6Al4V alloy. The kinematics of the 3D EVC was described, and then the influence of various cutting speeds, vibration amplitudes, vibration frequencies and depths of cut on cutting force and residual stress were carried out and analyzed. The simulation results show that the cutting speed, vibration amplitude a, vibration frequency and depth of cut have larger effect on principal force. In addition, the compressive stress layer can be easily obtained near the machined surface by using 3D EVC, which is helpful to improve the working performance of workpiece.