Fracture Mechanics-Based Modelling of Tool Wear in Machining Ti6Al4V Considering the Microstructure of Cemented Carbide Tools

Q2 Engineering

Journal of Machine Engineering Pub Date : 2024-06-07 DOI:10.36897/jme/189588

Hossein Gohari, Bin Shi, M. H. Attia, Rachid M'Saoubi

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引用次数: 0

Abstract

This study introduces a new wear model that can predict tool life in the milling process of Ti6Al4V using a cemented carbide tool. The model uses a finite element (FE) simulation to predict crack growth in the tool material microstructure. The FE model evaluates the crack propagation rate based on the real microstructure of the tool material, which is captured from microscopic images. To determine the normal and tangential forces operating on the flank face, an experimental procedure was developed based on three different flank wear widths. The FE model utilizes the elastic and fracture properties of tungsten carbide, and the elastic-plastic and fracture characteristics of cobalt binder to determine crack growth under the applied cutting forces. The crack propagation information combined with cutting conditions and the initial wear level are used to estimate the tool wear state. The developed model can predict tool life under different cutting conditions, tool geometries, and microstructure properties. Analysis of results showed that the error for the straight cuts was less than 6%, while for the complex cuts, it reached up to 20%. The accuracy of the model can be improved by extending the calibration test to higher levels of flank wear.

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基于断裂力学的加工 Ti6Al4V 时刀具磨损建模（考虑硬质合金刀具的微观结构

本研究介绍了一种新的磨损模型，该模型可预测使用硬质合金刀具铣削 Ti6Al4V 时的刀具寿命。该模型采用有限元（FE）模拟来预测刀具材料微观结构中的裂纹生长。有限元模型根据从显微镜图像中捕捉到的刀具材料真实微观结构评估裂纹扩展速率。为了确定作用在侧面的法向力和切向力，根据三种不同的侧面磨损宽度开发了一套实验程序。有限元模型利用碳化钨的弹性和断裂特性，以及钴粘结剂的弹塑性和断裂特性来确定外加切削力下的裂纹生长情况。裂纹扩展信息与切削条件和初始磨损程度相结合，用于估算刀具磨损状态。所开发的模型可以预测不同切削条件、刀具几何形状和微观结构特性下的刀具寿命。结果分析表明，直切削的误差小于 6%，而复杂切削的误差高达 20%。通过将校准测试扩展到更高的侧面磨损水平，可以提高模型的准确性。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Journal of Machine Engineering Engineering-Industrial and Manufacturing Engineering

CiteScore

2.70

自引率

0.00%

发文量

审稿时长

25 weeks

期刊介绍： ournal of Machine Engineering is a scientific journal devoted to current issues of design and manufacturing - aided by innovative computer techniques and state-of-the-art computer systems - of products which meet the demands of the current global market. It favours solutions harmonizing with the up-to-date manufacturing strategies, the quality requirements and the needs of design, planning, scheduling and production process management. The Journal'' s subject matter also covers the design and operation of high efficient, precision, process machines. The Journal is a continuator of Machine Engineering Publisher for five years. The Journal appears quarterly, with a circulation of 100 copies, with each issue devoted entirely to a different topic. The papers are carefully selected and reviewed by distinguished world famous scientists and practitioners. The authors of the publications are eminent specialists from all over the world and Poland. Journal of Machine Engineering provides the best assistance to factories and universities. It enables factories to solve their difficult problems and manufacture good products at a low cost and fast rate. It enables educators to update their teaching and scientists to deepen their knowledge and pursue their research in the right direction.