Toward a better understanding of tool wear effect through a comparison between experiments and SPH numerical modelling of machining hard materials
TypeArticles dans des revues avec comité de lecture
The aim of this study is to improve the general understanding of tungsten carbide (WC–Co) tool wear under dry machining of the hard-to-cut titanium alloy Ti6Al4V. The chosen approach includes experimental and numerical tests. The experimental part is designed to identify wear mechanisms using cutting force measurements, scanning electron microscope observations and optical profilometer analysis. Machining tests were conducted in the orthogonal cutting framework and showed a strong evolution of the cutting forces and the chip profiles with tool wear. Then, a numerical method has been used in order to model the machining process with both new and worn tools. The use of smoothed particle hydrodynamics model (SPH model) as a numerical tool for a better understanding of the chip formation with worn tools is a key aspect of this work. The predicted chip morphology and the cutting force evolution with respect to the tool wear are qualitatively compared with experimental trends. The chip formation mechanisms during dry cutting process are shown to be quite dependent from the worn tool geometry. These mechanisms explain the high variation of the experimental and numerical feed force between new and worn tools.
Showing items related by title, author, creator and subject.
CALAMAZ, Madalina; COUPARD, Dominique; GIROT, Franck (Taylor and Francis, 2010)In this study, the commercial finite element software FORGE2005, able to solve complex thermo-mechanical problems is used to model titanium alloy dry machining. One of the main machining characteristics of titanium alloys ...
A new material model for 2D numerical simulation of serrated chip formation when machining titanium alloy Ti-6Al-4V CALAMAZ, Madalina; COUPARD, Dominique; GIROT, Franck (Elsevier, 2008)A new material constitutive law is implemented in a 2D finite element model to analyse the chip formation and shear localisation when machining titanium alloys. The numerical simulations use a commercial finite element ...
CALAMAZ, Madalina; COUPARD, Dominique; GIROT, Franck (Trans Tech Publications, 2012)Improving the cutting processes by optimizing operating parameters necessarily involves understanding the thermo-mechanical mechanisms generated during chip formation. For this, numerical simulations are used to obtain ...
Mécanismes d'usure des outils coupants en usinage à sec de l'alliage de titane aéronautique Ti–6Al–4V NOUARI, Mohammed; CALAMAZ, Madalina; GIROT, Franck (Elsevier, 2008)In the present study, the titanium alloy ‘Ti–6Al–4V’ is orthogonally machined without cutting fluid. During experiments, the cemented carbide tools were rigidly mounted on the tool holder with rake angles of 0°, 15° and ...
POTTIER, Thomas; GERMAIN, Guénaël; CALAMAZ, Madalina; MOREL, Anne; COUPARD, Dominique (Springer, 2014)The present paper details a simple and effective experimental procedure dedicated to strain measurement during orthogonal cutting operations. It relies on the use of high frame-rate camera and optical microscopy. A numerical ...