Simulation and analytical studies of chip formation processes in the cutting zone of titanium alloys

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dc.citation.epage16
dc.citation.issue1
dc.citation.journalTitleУкраїнський журнал із машинобудування і матеріалознавства
dc.citation.spage1
dc.citation.volume9
dc.contributor.affiliationLviv Polytechnic National University
dc.contributor.affiliationKaunas University of Technology
dc.contributor.authorStupnytskyy, Vadym
dc.contributor.authorShe, Xianning
dc.contributor.authorDragašius, Egidijus
dc.contributor.authorBaskutis, Saulius
dc.contributor.authorProdanchuk, Oleh
dc.coverage.placenameЛьвів
dc.coverage.placenameLviv
dc.date.accessioned2024-02-07T08:18:44Z
dc.date.available2024-02-07T08:18:44Z
dc.date.created2023-02-28
dc.date.issued2023-02-28
dc.description.abstractThe low machinability of titanium alloys is determined by the physical, mechanical, and chemical properties of these materials and their mechanical characteristics. It is also evident in the hardened state of the material being processed during cutting and in the initial state. This phenomenon is caused by thermodynamic parameters that determine the properties of titanium material at elevated temperatures. The peculiarities of the cutting and chip formation processes during titanium alloy machining are presented in this article. The peculiarity of the described approach is the analysis of the results of simulation modeling of cutting in Deform 2D software. It is proved that the frictional factor in the formation of the thermal characteristics of the cutting process, which arises as a result of the chip sliding along the tool, dominates the load factor (caused by force and deformation processes in the chip root). It has been established that the length of contact between the chips and the tool’s rake face has a certain tendency to change: the contact length first increases and then decreases with increasing cutting speed. An analysis of the dependence of the chip compression ratio on changes in cutting speed has shown that with an increase in cutting speed, the average value of the compression ratio practically does not change, but the amplitude of its oscillation increases significantly, which is equivalent to a change in the shear angle. This parameter changes dynamically due to the adiabatic nature of chip formation.
dc.format.extent1-16
dc.format.pages16
dc.identifier.citationSimulation and analytical studies of chip formation processes in the cutting zone of titanium alloys / Vadym Stupnytskyy, Xianning She, Egidijus Dragašius, Saulius Baskutis, Oleh Prodanchuk // Ukrainian Journal of Mechanical Engineering and Materials Science. — Lviv : Lviv Politechnic Publishing House, 2023. — Vol 9. — No 1. — P. 1–16.
dc.identifier.citationenSimulation and analytical studies of chip formation processes in the cutting zone of titanium alloys / Vadym Stupnytskyy, Xianning She, Egidijus Dragašius, Saulius Baskutis, Oleh Prodanchuk // Ukrainian Journal of Mechanical Engineering and Materials Science. — Lviv : Lviv Politechnic Publishing House, 2023. — Vol 9. — No 1. — P. 1–16.
dc.identifier.doidoi.org/10.23939/ujmems2023.01.001
dc.identifier.urihttps://ena.lpnu.ua/handle/ntb/61132
dc.language.isoen
dc.publisherВидавництво Львівської політехніки
dc.publisherLviv Politechnic Publishing House
dc.relation.ispartofУкраїнський журнал із машинобудування і матеріалознавства, 1 (9), 2023
dc.relation.ispartofUkrainian Journal of Mechanical Engineering and Materials Science, 1 (9), 2023
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dc.relation.references[7] Stupnytskyy V. and Hrytsay I. “Simulation Study of Cutting-Induced Residual Stress”, Advances in Design, Simulation and Manufacturing. DSMIE-2019. Lecture Notes in Mechanical Engineering, vol. 1, pp. 341–350, 2020.
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dc.relation.references[12] Zhu X., Shi J., Liu Y., Jiang Y., Zhou B. and Zhao X. “Study on Formation Mechanism of Serrated Chip of Ti-6Al-4V Titanium Alloy Based on Shear Slip Theory” The International Journal of Advanced Manufacturing Technology, Preprint, 2022.
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dc.relation.references[15] Astakhov V. P. and Quteiro J. C. “Metal cutting mechanics, finite element modelling”, Machining, Springer, London, pp. 1–27, 2008.
dc.relation.references[16] García-Martínez E., Miguel V., Martínez-Martínez A., Manjabacas M. C. and Coello J. “Sustainable lubrication methods for the machining of titanium alloys: An overview”, Materials, vol. 12, no. 23, 3852, 2019.
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dc.relation.references[18] Hatt O., Crawforth P. and Jackson M. “On the mechanism of tool crater wear during titanium alloy machining”, Wear, vol. 374, pp. 15–20.
dc.relation.references[19] Perry J. (Ed.). Titanium Alloys: Types, Properties, and Research Insights. Nova Science Publishers, NY, 2017.
dc.relation.references[20] Niknam S. A., Khettabi R. and Songmene V. “Machinability and machining of titanium alloys: a review”. In book: Machining of Titanium Alloys: Chapter 1, Springer-Verlag, Berlin-Heidelberg, 2014.
dc.relation.references[21] Stupnytskyy V. and Xianning S. “Comparative Analysis of Simulation Results of Hard-to-Cut Materials Machining by Coated Cutting Tools”, Journal of Mechanical Engineering–Strojnícky časopis, vol. 70, no. 2, pp. 153–166, 2020.
dc.relation.references[22] Shihab S. K., Khan Z. A., Mohammad A. and Siddiquee A. N. “A review of turning of hard steels used in bearing and automotive applications”, Production & Manufacturing Research, vol. 2, no. 1, pp. 24–49, 2014.
dc.relation.references[23] Klocke F., Arntz K., Cabral G. F., Stolorz M. and Busch M. “Characterization of tool wear in high-speed milling of hardened powder metallurgical steels”, Advances in Tribology, Special Issue “Wear Related Phenomena in Advanced Materials”, 2011.
dc.relation.references[24] Kishawy H. A. and Hosseini A. Machining difficult-to-cut materials. Part of the book series: Materials Forming, Machining and Tribology, London: Springer, 2019.
dc.relation.references[25] Zadshakoyan M. and Pourmostaghimi V. “Genetic equation for the prediction of tool–chip contact length in orthogonal cutting”, Engineering Applications of Artificial Intelligence, vol. 26, no. 7, pp. 1725–1730, 2013.
dc.relation.referencesen[1] Astakhov V. P. Metal cutting mechanics, Boca Raton: CRC Press, 1998.
dc.relation.referencesen[2] Novikov F. V. and Benin E. Y. "Determination of conditions ensuring cost price reduction of machinery", Economics of Development, vol. 3, no 63, pp. 69–74, 2012.
dc.relation.referencesen[3] Davim J. P. and Astakhov V. P. "Tribology of Metal Cutting", International Journal of Machining and Machinability of Materials, vol. 5, no. 2/3, pp. 367–368, 2009.
dc.relation.referencesen[4] Ulutan D. and Ozel T. "Machining induced surface integrity in titanium and nickel alloys: A review", International Journal of Machine Tools and Manufacture, vol. 51, no. 3, pp. 250–280, 2011.
dc.relation.referencesen[5] Davim J. P. Machining of Titanium Alloys, Materials Forming, Machining and Tribology. London: Springer, 2014.
dc.relation.referencesen[6] Davim J. P. (Ed.), Machining of hard materials. London: Springer Science & Business Media, 2011.
dc.relation.referencesen[7] Stupnytskyy V. and Hrytsay I. "Simulation Study of Cutting-Induced Residual Stress", Advances in Design, Simulation and Manufacturing. DSMIE-2019. Lecture Notes in Mechanical Engineering, vol. 1, pp. 341–350, 2020.
dc.relation.referencesen[8] Xu W. J., Zhang X. M., Leopold J. and Ding H. "Mechanism of serrated chip formation in cutting process using digital image correlation technique", Procedia CIRP, vol. 58, 146–151, 2017.
dc.relation.referencesen[9] Ye G. G., Chen Y., Xue S. F. and Dai L. H. "Critical cutting speed for onset of serrated chip flow in high speed machining", International Journal of Machine Tools and Manufacture, vol. 86, pp. 18–33, 2014.
dc.relation.referencesen[10] Devotta A., Beno T., Siriki R., Löf R. and Eynian M "Finite element modeling and validation of chip segmentation in machining of AISI 1045 steel", Procedia Cirp, vol. 58, pp. 499–504, 2017.
dc.relation.referencesen[11] Wen L., Yang C. Q., Niu Q. L., Ming W. W. and Chen M. "Experimental Study on the Formation Mechanism of Serrated Chip of TC11 Titanium Alloy", Key Engineering Materials, vol. 693, pp. 767–774, 2016.
dc.relation.referencesen[12] Zhu X., Shi J., Liu Y., Jiang Y., Zhou B. and Zhao X. "Study on Formation Mechanism of Serrated Chip of Ti-6Al-4V Titanium Alloy Based on Shear Slip Theory" The International Journal of Advanced Manufacturing Technology, Preprint, 2022.
dc.relation.referencesen[13] Rahman M., Wang Z. G. and Wong Y. S. "A review on high-speed machining of titanium alloys". JSME International Journal Series C, Mechanical Systems, Machine Elements and Manufacturing, vol. 49, no. 1, pp. 11–20, 2006.
dc.relation.referencesen[14] Calamaz M., Coupard D., Nouari M. and Girot F. "Numerical analysis of chip formation and shear localisation processes in machining the Ti-6Al-4V titanium alloy" The International Journal of Advanced Manufacturing Technology, vol. 52, no. 9, pp. 887–895, 2011.
dc.relation.referencesen[15] Astakhov V. P. and Quteiro J. C. "Metal cutting mechanics, finite element modelling", Machining, Springer, London, pp. 1–27, 2008.
dc.relation.referencesen[16] García-Martínez E., Miguel V., Martínez-Martínez A., Manjabacas M. C. and Coello J. "Sustainable lubrication methods for the machining of titanium alloys: An overview", Materials, vol. 12, no. 23, 3852, 2019.
dc.relation.referencesen[17] Pramanik A. "Problems and solutions in machining of titanium alloys", The International Journal of Advanced Manufacturing Technology, vol. 70, no. 5, pp. 919–928, 2014.
dc.relation.referencesen[18] Hatt O., Crawforth P. and Jackson M. "On the mechanism of tool crater wear during titanium alloy machining", Wear, vol. 374, pp. 15–20.
dc.relation.referencesen[19] Perry J. (Ed.). Titanium Alloys: Types, Properties, and Research Insights. Nova Science Publishers, NY, 2017.
dc.relation.referencesen[20] Niknam S. A., Khettabi R. and Songmene V. "Machinability and machining of titanium alloys: a review". In book: Machining of Titanium Alloys: Chapter 1, Springer-Verlag, Berlin-Heidelberg, 2014.
dc.relation.referencesen[21] Stupnytskyy V. and Xianning S. "Comparative Analysis of Simulation Results of Hard-to-Cut Materials Machining by Coated Cutting Tools", Journal of Mechanical Engineering–Strojnícky časopis, vol. 70, no. 2, pp. 153–166, 2020.
dc.relation.referencesen[22] Shihab S. K., Khan Z. A., Mohammad A. and Siddiquee A. N. "A review of turning of hard steels used in bearing and automotive applications", Production & Manufacturing Research, vol. 2, no. 1, pp. 24–49, 2014.
dc.relation.referencesen[23] Klocke F., Arntz K., Cabral G. F., Stolorz M. and Busch M. "Characterization of tool wear in high-speed milling of hardened powder metallurgical steels", Advances in Tribology, Special Issue "Wear Related Phenomena in Advanced Materials", 2011.
dc.relation.referencesen[24] Kishawy H. A. and Hosseini A. Machining difficult-to-cut materials. Part of the book series: Materials Forming, Machining and Tribology, London: Springer, 2019.
dc.relation.referencesen[25] Zadshakoyan M. and Pourmostaghimi V. "Genetic equation for the prediction of tool–chip contact length in orthogonal cutting", Engineering Applications of Artificial Intelligence, vol. 26, no. 7, pp. 1725–1730, 2013.
dc.rights.holder© Національний університет “Львівська політехніка”, 2023
dc.rights.holder© Stupnytskyy V., She X., Dragašius E., Baskutis S., Prodanchuk O., 2023
dc.subjecttitanium alloy
dc.subjectcutting
dc.subjectstress-strain state
dc.subjectadiabatic shear
dc.subjectchip compression ratio
dc.titleSimulation and analytical studies of chip formation processes in the cutting zone of titanium alloys
dc.typeArticle

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Ukrainian Journal of Mechanical Engineering and Materials Science. – 2023. – Vol. 9, No. 1