Abstract
A numerical simulation analysis of mechanical chip morphology and residual stress for Ti6Al4V alloy was conducted under different cutting speed and feed rate. Johnson-Cook constitutive model and shear failure model were selected in the simulation procedure. The correlations between the mechanical chip morphology and surface residual stress were detailed. The results show that the chip morphology characterized with the degree of serration Gs and the serrated frequency f has a direct impact on residual stress distribution. With the increase of the degree of serration Gs, the maximum residual tensile stress decreases, while with the increase of the serrated frequency f, the maximum residual compressive stress increases on the surface. The research of the present paper provides a new way to understand and evaluate residual stress distribution for titanium alloy mechanical process.
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Abbreviations
- \({\bar \sigma}\) :
-
Equivalent stress
- \({{\bar \varepsilon}^{pl}}\) :
-
Equivalent plastic strain
- \({{\dot \varepsilon}_0}\) :
-
Strain rate
- \({{\dot \bar \varepsilon}^{pl}}\) :
-
Reference strain rate
- T room :
-
Room temperature of Ti6Al4V
- T melt :
-
Melting temperature of Ti6Al4V
- D:
-
Damage variable (stiffness degradation factor)
- G f :
-
Fracture energy
- L :
-
Element characteristic length
- \(\bar u\) :
-
Equivalent plastic displacement
- σ y :
-
Yield strength of the material
- h 1 :
-
Height of the peak
- h 2 :
-
Height of the valley
- d :
-
Spacing of the serrated chip
- f :
-
Geometrical characterization parameters of the serrated frequency
- G s :
-
Geometrical characterization parameters of the degree of serration
- V :
-
Cutting speed
- ϕ :
-
Adiabatic shear angle
- d :
-
Spacing of the serrated chip
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Acknowledgments
The present research was supported by the Jiangsu Province Natural Science Foundation of China (No. BK20180440).
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Z. R. Wu currently teaches in the College of Energy and Power Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, Jiangsu, China. He received his Ph.D. from Nanjing University of Aeronautics and Astronautics, China, in 2014. His research interests include fatigue and durability of components and structures.
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Wu, Z.R., Zhu, K.K., Pan, L. et al. Investigation of the correlation between mechanical chip morphology and surface residual stress for Ti6Al4V alloy. J Mech Sci Technol 34, 3997–4004 (2020). https://doi.org/10.1007/s12206-020-2210-0
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DOI: https://doi.org/10.1007/s12206-020-2210-0