Modeling of Cutting Forces for High-speed Milling of Titanium Alloys

Prof. M. Rahman and Wang Zhigang Dept of Mechanical Engineering

Overview
Introduction Literature review Modeling of milling process Modeling of cutting forces for highspeed milling of Ti-6Al-4V Verification of the cutting force model Conclusions
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Introduction
Cutting temperature as a result of cutting speed

Introduction
Definition of high-speed machining (HSM)
fibre-reinforced plastics aluminum alloys bronze, brass cast iron steel titanium alloys
nickel based alloys

ra ng e

co nv en tio na l

ra ng e n

tra ns iti o

10

100

1000

HS

Cra ng e

10000

cutting speed vc [m/min]

Cutting Speed Area Depends on Material

Introduction (contd.)
Significant advantages of HSM
Higher productivity Generate high-quality surfaces, burr-free edges and stress-free components. Cutting forces are lower Minimize the heat effect on machined parts; eliminate the usage of cutting fluids
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Introduction (contd.)
Applications of HSM
HSM is a strategic part of making F/A-18E/F tactical fighters

Aircraft & aerospace production, tool and die mold manufacturing (high productivity) Optical industry, fine mechanical parts (high surface quality) Precision mechanics, magnesium alloys (Cutting heat taken away by chips) Automotive industry, household equipments (low cutting forces)
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Introduction (contd.)
Titanium alloys have been widely used in the aerospace, biomedical, automotive and petroleum industries because of
their good strength-to-weight ratio superior corrosion resistance.

Their machinability is very poor. Among all titanium alloys, Ti-6Al-4V is most widely used.
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Introduction (contd.)
High-speed machining of Ti-6Al-4V
The performance of conventional tools is poor Advanced tool materials, such as cubic boron nitride (CBN), polycrystalline diamond (PCD) Binderless CBN used in this study Experiments are costly and time-consuming
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Literature review
Survey of recent research on modeling by CIRP working group
15 topics related to modeling of machining operations Six major operational groups: single straight edge orthogonal, single straight edge oblique, turning, milling, drilling and form-tool machining

Over 55 major research group are currently active in modeling efforts

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Literature review (contd.)

Three categories of cutting force modeling
Experimental/empirical modeling (43% of research groups) Analytical modeling (32% of research group) Numerical modeling (18% of research group)

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Literature review (contd.)

Empirical model
Taylor, the father of metal cutting science, firstly used empirical approach to propose the well-known Taylors equation The power-law form of Taylor equation extended to predict cutting forces

F = Ca f v

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Literature review (contd.)

Empirical model
Only valid for particular cutter geometry and workpiece combination; Large numbers of empirical experiments are required; This method is not suitable for cutting tool design purpose
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Literature review (contd.)

Analytical model
Mechanistic model Shear plane model Shear zone model Predictive machining theory

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Literature review (contd.)

Mechanistic model
Based on the assumption that the magnitude of cutting forces depend on the uncut area Tangential force in milling is given as:

Ft = K t A
where Kt is the specific cutting pressure, A is the uncut chip area; Limits: Kt depend on specific combination of tool/workpiece
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Literature review (contd.)

Shear plane model
Initiated by Merchants shear plane theory Use the minimum energy principle to determine the shear angle Shear plane theory assumes that thin shear zone is a plane, and that work material deforms at constant flow stress
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Literature review (contd.)

Shear zone model
Strain hardening properties of the work material had a profound effect on the hydrostatic stress distribution in the chip formation zone. Oxley and Welsh (1963) introduced the parallel-sided shear zone model of chip formation.
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Literature review (contd.)

Shear zone model
Tool Chip
E C A

VC

F D B

Between the boundary of CD and EF

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Literature review (contd.)

Oxleys predictive machining theory
Based on the parallel-sided shear zone model The flow stress of a metal is influenced by:
properties of work material effective strain effective rate of deformation or strain rate cutting temperature
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Literature review (contd.)

Numerical modeling
Mostly use the finite element method (FEM) More accurate than the analytical model Predict cutting forces, strain, strain rate and temperature, etc. FEM requires much more computation time, especially for 3-D simulation
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Modeling of milling process

Relative motion between the cutting tool and workpiece for face milling:
Rotation of the spindle Translational motion of feed

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Modeling of milling process (contd.)

Traditional trochoid curve

The motion of the cutter is like the trace of a point fixed on a circle that rolls along a line
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Modeling of milling process (contd.)

Traditional undeformed chip thickness
f h A R

h ( ) = f sin( )
f

O
O

For high speed milling or micro-milling, there is a great need for higher accuracy, so the circular tooth-pass could not meet the requirement
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Modeling of milling process (contd.)

The true tool trajectory during slot milling
Tool tip B True tool trajectory

O A O D Chip thickness Workpiece

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Modeling of milling process (contd.)

Analytical solution to undeformed chip thickness

2 sin( ) a 2a = 0
where

f a = sin( ) and = 0 - R 2

cos( ) cos( ) h( ) = BC = R CD = R cos( )

1 2 3 + 2 2 3 3 + 8 2 4 where = a + a + a + a + O (a 5 ) 2 12 2 24 3
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Modeling of milling process (contd.)

Effects of nose radius
dFr d r dFt r-a E
F

II I A

B 2

1
O

h()

h()

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Modeling of milling process (contd.)

Non-uniform chip area
2 2 1 1 2 ( r a ) 2 1 1 2 1 2 2 S = ( r OB )d + ( r AO )d = ( r )d + 2 0 1 0 2 2 2 sin

1 2 2 [h ( ) sin 2 + 2h( ) cos r 2 h 2 ( ) sin 2 h 2 ( ) cos2 ]d 2 1

It needs to establish a model about 3-D milling process to simulate the cutting process around the tool tip
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Modeling of milling process (contd.)

Equivalent element representation
Represent the uneven uncut chip area with the equivalent rectangular contact area Represent the uneven intersection surface with the equivalent one which is suitable for axisymmetric deformation simulation (Ozel, 1998)

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Modeling of milling process (contd.)

Equivalent element representation
FZ he r r-a B A
0 e 3

Ft

Fr

Fr C D

h()

h()

When chip thickness is less than 0.05mm, the size effect is very obvious.

Equivalent element representation with a parallelogram

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Modeling of cutting force

Overview of this section
Brief review of Oxleys theory Deformation behavior of Ti-6Al-4V Hybrid cutting force between Oxleys theory and FEM simulation

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Modeling of cutting force (contd.)

Oxleys predictive cutting force theory
His model has been widely used by many researchers Two limitations: Two assumptions: cutting edge is perfectly sharp; uniform normal stress distributes at the tool/chip interface His work was mainly focused on the carbon steel work material
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Modeling of cutting force (contd.)

Cutting force diagram based on shear zone model
t2 Chip
E A C FN

Tool

Ff

G
Fn

FR

VC lc

FS FR Fc FT

t1

D F

Based on the parallel-sided shear zone model

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Modeling of cutting force (contd.)

Geometric and cutting forces relations:
VC sin Vchip = cos( ) VC cos VS = cos( ) t2 = t1 cos( ) / sin
FS FR = cos

= +
tan = 1 + 2( / 4 ) Cn

k AB t1w cos( ) FC = FR cos( ) = sin cos k AB t1w sin( ) FT = FR sin( ) = sin cos

kAB, , n and C ?????

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Modeling of cutting force (contd.)

Oxleys predictive cutting forces theory:
Shear flow stress kAB along the shear plane
k AB = 1 AB / 3
n

where 1 is initial stress constant, and n is strain-hardening index, AB is effective strain along the shear plane. 1 and n vary with strain rate and temperature

Effective strain and strain-rate are calculated as

AB = AB / 3 & AB = &AB / 3 & AB where AB and are maximum strain and strain rate along
AB
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Modeling of cutting force (contd.)

Oxleys predictive cutting forces theory:
Maximum strain and strain rate along AB
AB
1 cos = 2 sin cos( )

&AB = C

VS l

where l is the length of AB, and C is strain-rate constant.

Velocity modified temperature

& & Tmod = TAB [1 v lg( / 0 )]

where TAB is the cutting temperature at shear plane AB, the constants v and 0 are taken as 0.09 and 1/sec &
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Modeling of cutting force (contd.)

Oxleys predictive cutting forces theory:
Temperature at shear plane AB

TAB = TW + TSZ
where TW is the initial workpiece temperature and TSZ can be calculated from the equation:

1 FS cos TSZ = St1w cos( )

TAB depends on cutting forces and thermal properties of workpiece material.
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Modeling of cutting force (contd.)

Computation about the cutting temperature in the shear zone
Assume TAB=Tw

TAB = new TAB

Calculate for plane AB, thermal properties S and K; Tmod, kAB; FS = kABlw; RT and ; TSZ and TAB

a small given value Compare new TAB and old TAB a small given value

Calculate ; ; R=FS/cos, F, N and FC

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Modeling of cutting force (contd.)

Mean chip temperature calculation:
Assume mean chip temperature TC=Tw + TSZ

TC = new TC

Calculate the chip thermal properties S and K from appropriate equations; TC; TC =Tw + TSZ + TC

a small given value Compare new TC and old TC a small given value Calculate for the toolchip interface shear flow stress kchip = 1/3

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Modeling of cutting force (contd.)

Oxleys predictive cutting forces theory:
Shear flow stress at the tool-chip interface 1
k chip =
where 1 corresponds to the value of Tmod. This equation neglects the influence of strain on the flow stress above a strain of one.

Average shear stress at the tool-chip interface Ff t sin Cn int = where contact length l = cos sin 1 + 3[1 + 2( / 4 ) Cn] lc w
c 1

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Modeling of cutting force (contd.)

Solution to shear angle
600 Shear stress (MPa)

kchip

int

Shear angle (deg)

45

The solution to is taken at the intersection of the two curves.

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Modeling of cutting force (contd.)

Determination of strain-rate constant
The tool-chip interface is assumed to be a direction of maximum shear stress, the normal stress N at B is given by N ' = 1 + 2 2Cn
k AB 2

Based on the assumption of uniform normal stress along the tool-chip interface, the normal stress N at B is also given by

FN N = wlc

C can be found by fulfilling the condition N = N

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Modeling of cutting force (contd.)

Summary of the machining calculations
For a given and C, the equilibrium values of are found (when int is equal to the value of kchip). Then, the required value of C is determined from the stress boundary condition. The above procedure is iterated for a given range of and C until all the equilibrium conditions are fulfilled.
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Modeling of cutting force (contd.)

Given: cutting conditions: , U, t1, w, Tw and material properties; Assign values for 1, 2, , final

= i
Assume the initial value of C (say C = 5) Assume (say = 5o) Calculate l = t1/sin ; VS, AB andAB; Estimate new C Calculation of temperature at shear plane Calculate ; ; R=FS/cos, F, N and FC Calculate the flow stress int at tool/chip interface
No

= + 0.1o

Calculate the mean temperature at the chips Calculate the tool/chip interface shear flow stress kchip
a small given value Compare N and N a small given value No =final? Yes Plot Fc versus and determine =min for minimum Fc

=45o?
Yes

Plot int and kchip versus and select solution point where int=kchip
=min?
Yes

=min

No Print the final results, such as , forces etc

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Modeling of cutting force (contd.)

Summary of the machining calculations
Five iterative procedures involved in the computation: determination of temperature at AB, and at tool-chip interface, possible ranges of C, and . These three parameters are very important for its accuracy. Such a procedure is extremely time-consuming.
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Modeling of cutting force (contd.)

Modeling of flow stress properties of Ti-6Al-4V
Johnson-Cook (JC) strength model represents the flow stress of a material as the product of strain, strain-rate and temperature:
& T Tr m = [ A + B ( ) ][1 + C ln( )][1 ( ) ] &0 Tm Tr
n

Then, differentiate with respect to :

& d T Tr m nB( AB ) n 1 n 1 = nB( AB ) [1 + C ln( )][1 ( ) ]= AB n &0 d Tm Tr [ A + B ( AB ) ]
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Modeling of cutting force (contd.)

20oC 700oC

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Modeling of cutting force (contd.)

Modeling of cutting forces
In Oxleys model (1989), flow stress in the shear plane zone, kAB can be calculated according to:

k AB = 1 AB / 3
n

This is replaced by:

k AB = / 3
where is the effective flow stress along AB, which can be calculated using the constitutive equation.
46

Modeling of cutting force (contd.)

Modeling of cutting forces
The change rate of flow stress (dk/ds2) normal to AB can be assumed to be only related to the actual strain-rate

dk dk d dk d dt = = ds2 d ds2 d dt ds2

(1)

Then, the first term on the right-hand side of above equation can be obtained as:

dk d / 3 nB( AB ) n 1 = = k AB n d 3d 3[ A + B( AB ) ]

(2)

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Modeling of cutting force (contd.)

Modeling of cutting forces
The second term on the R.H.S of Eq. (1) is the strain-rate

d VC cos =C dt l cos( )
The last term is the reciprocal of the cutting speed normal to AB, which can be presented as
dt 1 = ds2 VC sin( )
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Modeling of cutting force (contd.)

Modeling of cutting forces
Eq. (1) can be simplified as:
dk k AB nB( AB ) n 1 CVC cos 1 2k ABCnB( AB ) n = = n ds2 3[ A + B( AB ) ] cos( )l VC sin l[ A + B( AB ) n ]
(3)

According to the stress equilibrium equation along AB from Oxley (1989), the following relation exists

dk dp = ds1 ds2
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Modeling of cutting force (contd.)

Modeling of cutting forces
By applying the equation along AB, substituting for dk/ds2 from Eq. (3), the next equation is given
2k ABCnB( AB ) n p A pB = [ A + B( AB ) n ]
where pA and pB are the hydrostatic stresses at points A and B

Finally the unknown parameter C is given by

( p A pB )[ A + B( AB ) n ] C= 2k AB nB ( AB ) n
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Modeling of cutting force (contd.)

Modeling of cutting forces
In Oxleys theory, the angle made by the resultant force R with AB is expressed as
k l tan = 1 + 2( ) 4 2k AB s2

The following equation is obtained

B AB tan = 1 + 2( ) Cn n 4 A + B AB
n
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Modeling of cutting force (contd.)

Modeling of cutting forces
Based on above description, for given values of tool rake angle , the cutting speed VC, the thickness t1 and width of cut w of the undeformed chip, together with the thermal and flow stress properties of the workpiece material and the initial temperature of the work Tw (say, 20oC in all calculations), FEM can be employed to simulate the metal deformation process .
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Verification of the model

Experimental setup

Cutter workpiece dynamometer Work table

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Verification of the model (contd.)

Experimental design and cutting conditions
Cutting tools: binderless cubic boron nitride Cutting conditions
Cutting speed: 300, 350 and 400 (m/min) Feed rate: 0.075, 0.100 and 0.125 (mm/r)

Depth of cut: 0.075, 0.010 and 0.125 (mm)

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Verification of the model (contd.)

Deformation zone of FEM simulation

Effects of cutting edge radius has been considered

55

Verification of the model (contd.)

Temperature distribution on the tip of the tool

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Verification of the model (contd.)

Temperature simulation

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Verification of the model (contd.)

(a) Estimated cutting forces
40 30 Cutting forces (N) 20 10 0 0 -10 Angular position (deg) -20 45 90 135 180 Fx (N) Fy (N) Fz (N)

(b) Experimental cutting forces

50 40 Cutting forces (N) 30 20 10 0 0 -10 Angular position (deg) -20 45 90 135 180 Fx (N) Fy (N) Fz (N)

at a = 0.075mm, f = 0.075mm/r and v = 350m/min

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Verification of the model (contd.)

(a) Estimated cutting forces
80 70 60 Cutting forces (N) 50 40 30 20 10 0 -10 0 -20 45 90 135 Angular position (deg) 180
-20 Angular position (deg) -40

(b) Experimental cutting forces

Fx (N) Fy (N) Fz (N)
100 80 Cutting forces (N) 60 40 20 0 0 45 90 135 180 Fx (N) Fy (N) Fz (N)

at a = 0.10mm, f = 0.1mm/r and v = 350m/min

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Verification of the model (contd.)

(a) Estimated cutting forces
70 60 50 Cutting forces (N) 40 30 20 10 0 -10 0 -20 -30 45 90 135 180 Fx (N) Fy (N) Fz (N) Cutting forces (N)

(b) Experimental cutting forces

80 70 60 50 40 30 20 10 0 -10 0 -20 45 90 135 Angular position (deg) 180 Fx (N) Fy (N) Fz (N)

Angular position (deg)

a = 0.10mm, f = 0.1mm/r and v = 400m/min

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Conclusions
Analytical solution to undeformed chip thickness is derived; JC model is used to describe the deformation behavior of the workpiece material; After FEM simulation, a new cutting force model for high-speed milling of Ti-6Al-4V is proposed; The cutting forces can be predicted with reasonable accuracy for all three directions.
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Thank you for your attention!!!

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