Influence of cutting velocity on surface roughness during the ultra-precision cutting of titanium alloys based on a comparison between simulation and experiment

• Published in: PloS one 2023-07, Vol.18 (7), p.e0288502-e0288502
• Main Authors: Lou, Yonggou, Chen, Lei, Wu, Hongbing, To, Sandy
• Format: Article
• Language: English
• Subjects: Aerospace industry; Aircraft; Alloys; Analysis; Computer and Information Sciences; Constitutive models; Corrosion resistance; Cutting force; Cutting parameters; Cutting speed; Cuttings; Damage assessment; Evaluation; Finite element method; Friction; Heat conductivity; Heat resistance; Heat transfer; Machinability; Machining; Mathematical models; Mechanical properties; Metal-cutting; Modelling; Morphology; Physical Sciences; Precision machining; Properties; Research and Analysis Methods; Simulation; Surface Properties; Surface roughness; Thermal resistance; Titanium; Titanium alloys; Titanium base alloys; Tool wear; Turning (machining); Velocity
• ISSN: 1932-6203; 1932-6203
• DOI: 10.1371/journal.pone.0288502

The Ti-6Al-4V titanium alloy is a kind of light alloy material with high specific strength, corrosion resistance and heat resistance. Because of its excellent performance, it has become an important material in aerospace industry. However, this kind of alloy has very poor machinability, and rapid tool wear is a very serious problem in titanium alloy processing. At present, it is difficult to guarantee the ultra-precision machining quality of titanium alloy materials, which limits its application in high-tech fields. In order to solve this problem, the influence of cutting speed on ultra-precision cutting process of titanium alloy was analyzed comprehensively. and it was found that better surface quality could be obtained at lower cutting speed. In order to study the influence of cutting speed in ultra-precision cutting of titanium alloys, cutting experiments have been carried out. Additionally, a finite element model was established to analyze the ultra-precision cutting process. Also, the constitutive model, damage model, friction model, and heat transfer in the modeling process were discussed. The chip morphology, cutting temperature, cutting force, and surface morphology under different cutting velocities are analyzed by simulation. Then, the simulation results were compared with the experimental results. The findings show that cutting speed has great influence on the ultra-precision turning of the Ti-6Al-4V alloy and the surface roughness obtained by ultra-precision cutting of titanium alloy can be lower than 20 nm at a lower cutting speed.