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Effect of cutting process adjustment on crystallographic texture of machined surface layer of titanium alloy

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Abstract

Integral structural parts of titanium alloy have high material removal rate, high machining difficulty and need multi-step machining to form the final geometry. The crystallographic texture of machined surface layer will affect the surface quality and the mechanical performance of machined parts from the microstructural aspect. Therefore, high requirements for finish machining surface quality and a reasonable high-quality machining surface-oriented process adjustment method need to be explored. In this paper, the surface quality controlling methods of titanium alloy machining are theoretically analyzed, two machining process adjustment methods in terms of multi-step cutting and prestressed cutting are proposed, and the finite element simulation of multi-step cutting and prestressed cutting was carried out. According to the principle of crystallographic texture and the obtained shear strain and strain rate data by finite element simulation, the crystallographic texture of surface layer materials processed by single-step cutting, single-step prestressed cutting, multi-step cutting and prestressed multi-step cutting were simulated by viscoplastic self-consistent (VPSC) texture simulation program. The influence of cutting process adjustment method on the texture polar figures (texture type and texture density) and crystallographic orientation distribution function (ODF) diagram of machined surface was analyzed. Moreover, the experimental comparisons and validations of simulated results were conducted by orthogonal cutting tests and microstructural texture measurements by using electron backscatter diffraction (EBSD) technique.

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Data availability

The datasets generated and analyzed during the current study are available from the corresponding author on reasonable request.

Code availability

Not applicable.

Abbreviations

a c :

Cutting thickness

a ch :

Chip thickness

ξ :

Deformation coefficient

\(\phi\) :

Shear angle

\({\gamma }_{0}\) :

Tool rake angle

\(\varepsilon\) :

Average shear strain

\(\dot{\varepsilon }\) :

Average strain rate

v :

Cutting speed

\(\Delta y\) :

Distance between two slip planes

\(\mathrm{d}\left\{\sigma \right\}\) :

Residual stress

\({\left[D\right]}_{ep}\) :

Material plasticity matrix

\(\mathrm{d}{\left\{\varepsilon \right\}}_{F}\) :

Mechanical strain

\(\mathrm{d}{\left\{\varepsilon \right\}}_{T}\) :

Thermal strain

\(\mathrm{d}{\left\{\sigma \right\}}_{T}\) :

Thermal stress

\(\mathrm{d}{\left\{\sigma \right\}}_{Y}\) :

Prestress

\(\overline{\sigma }\) :

Equivalent flow stress

\(\overline{\varepsilon }\) :

Equivalent plastic strain rate

\({\overline{\varepsilon }}_{0}\) :

Reference plastic strain rate

A :

Yield strength

T room :

Room temperature

B :

Hardening modulus

C :

Strain rate sensitivity coefficient

M :

Thermal softening coefficient

T melt :

Melting temperature

T :

Absolute temperature

N:

Strain hardening exponent

D :

Damage

Δε :

Increment of equivalent plastic strain in an integration cycle

ε f :

Equivalent plastic strain to fracture under the current conditions of strain rate, temperature, pressure and equivalent stress

σ m :

Ydrostatic pressure

d 1 , d 2 , d 3 , d 4 , d 5 :

Damage failure material constants

τf :

Frictional shear stress

μ :

Friction coefficient

σ n :

Normal stress applied to the chip contact surface

τs :

Shear strength

f :

Feed rate

v 1 :

Cutting speed of the first cutting step

v 2 :

Cutting speed of the second cutting step

f 1 :

Feed rate of the first cutting step

f 2 :

Feed rate of the second cutting step

\(\varepsilon\) xx :

Longitudinal plastic strain

\(\varepsilon\) yy :

Transverse plastic strain

γ xy :

Plastic shear strain

S 11 :

Normal stress

g :

Crystallographic orientation

\(({\varphi }_{1},\phi , {\varphi }_{2})\) :

Sequential rotation angle about the axis of the crystal coordinate system

\(\stackrel{\nabla }{\tau }\) :

Jaumann rigid body derivative

τ:

Kirchhoff stress tensor

W:

Rotary rate tensor

D:

Tensor of deformation rate

P:

Tensor of the slip shear rate

Fp :

Evolution rate of deformation gradient

\(\stackrel{*}{{\gamma }^{\left(\alpha \right)}}\) :

Slipping rate of the slip system α

\({\tau }^{\left(\alpha \right)}\) :

Critical resolved shear stress (CRSS)

\(\stackrel{*}{{\gamma }_{0}}\) :

Reference slipping rate

\({g}^{\left(\alpha \right)}\) :

Strain hardening function

\({g}_{0}^{\left(\alpha \right)}\) :

Initial CRSS

\({g}_{1}^{\left(\alpha \right)}\) :

Saturation CRSS

Γ :

Taylor cumulative shear strain on all the activated slip systems

\({\theta }_{0}^{\left(\alpha \right)}\) :

Initial hardening rate

\({\theta }_{1}^{\left(\alpha \right)}\) :

Ultimate hardening rate

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Funding

The authors would like to acknowledge the financial supports of the Natural Science Foundation of Shandong Province (ZR2021ME043), the National Natural Science Foundation of China (51605260), the Key Research and Development Program of Shandong Province (2019JZZY010114) and the Young Scholars Program of Shandong University (2018WLJH57).

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Authors and Affiliations

  1. Key Laboratory of High Efficiency and Clean Mechanical Manufacture of MOE, School of Mechanical Engineering, Shandong University, Jinan, 250061, People’s Republic of China

    Anhai Li, Rufeng Zhang, Jinyuan Liu & Xuhao Song

  2. National Demonstration Center for Experimental Mechanical Engineering Education (Shandong University), Jinan, 250061, People’s Republic of China

    Anhai Li, Rufeng Zhang, Jinyuan Liu & Xuhao Song

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  1. Anhai Li
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Contributions

A.L. and X.S. were responsible for conceptualization and visualization; A.L., J.L., R.Z. and X.S. were involved in methodology; R.Z. and X.S. contributed to software; A.L. and R.Z. carried out validation; A.L., J.L. and R.Z. performed formal analysis; A.L., R.Z. and X.S. conducted investigation and data curation; A.L., J.L. and X.S. wrote the original draft, and wrote, reviewed and edited the manuscript; and A.L. took part in supervision, project administration and funding acquisition. All authors have read and agreed to the published version of the manuscript.

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Correspondence to Anhai Li.

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Li, A., Zhang, R., Liu, J. et al. Effect of cutting process adjustment on crystallographic texture of machined surface layer of titanium alloy. Archiv.Civ.Mech.Eng 23, 19 (2023). https://doi.org/10.1007/s43452-022-00563-w

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