Process Mechanics – a Guide for Industry 4.0: Modelling Cutting of Nimonic 90 and Ti-6Al-4V

W. Lortz, Radu Pavel
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Abstract

The chip formation models developed to date give no exact representation of the physics phenomena occurring during the complex machine cutting process. Despite the large number of investigations and simulations, there is still limited clarity of the real chip formation process. The models try to solve the plastic flow through force or stress simulation, without proper regard to adequate process mechanics. Due to these circumstances, practical evidence is missing. Analyzing this situation very carefully, some scientists founded the Industry 4.0 initiative to create scientific space with new opportunities. Whereas second and third industrial revolutions have been focused on organization and automation — Industry 4.0 is focused on technology, data integration and artificial intelligence (AI). However, before teaching a computer AI, the adequate process mechanics should be systematically developed and understood. This paper presents the complex process mechanics of chip formation with non-linear conditions in the metal microstructure, with two different friction zones, with self-hardening or temperatures effects. These entire phenomena can’t be solved separately because they have an interdependent relationship. The developed mathematical equations for strain and stress lead to square grid deformation in the chip formation zone, and this grid deformation does not disappear after completing the process, so that the theoretical development can be compared with practical results. This will be presented for two different materials Nimonic 90 and Ti-6Al-4V. For Nimonic 90 a built-up-edge (BUE) will be identified, and this is based on the stream-line inflow-angle. Quite contrary is the chip formation process for Ti-6Al-4V. A diffusion process in the interface chip-tool take place resulting in a self-blockade with segmented chip. In addition, the developed temperatures during cutting could be estimated and will be presented for the two different creep-resistant alloys. Finally, a high agreement between the theoretical and experimental results could be documented.
工艺力学-工业4.0指南:Nimonic 90和Ti-6Al-4V的建模切割
迄今为止开发的切屑形成模型并不能准确地表示复杂的机器切削过程中发生的物理现象。尽管进行了大量的研究和模拟,但对真实芯片形成过程的清晰度仍然有限。这些模型试图通过力或应力模拟来解决塑性流动,而没有适当考虑足够的过程力学。由于这些情况,缺乏实际证据。一些科学家非常仔细地分析了这种情况,创立了工业4.0倡议,以创造新的科学空间。第二次和第三次工业革命的重点是组织和自动化,而工业4.0的重点是技术、数据集成和人工智能(AI)。然而,在教授计算机人工智能之前,应该系统地开发和理解适当的过程机制。本文介绍了金属微观结构非线性条件下切屑形成的复杂过程机制,包括两种不同的摩擦区、自硬化或温度效应。这些整体现象不能单独解决,因为它们是相互依存的关系。所建立的应变和应力数学方程导致切屑形成区出现方形网格变形,且该网格变形在完成过程后不会消失,从而使理论发展与实际结果相比较。这将介绍两种不同的材料Nimonic 90和Ti-6Al-4V。对于Nimonic 90,将确定一个内置边缘(BUE),这是基于流线流入角。Ti-6Al-4V的晶片形成过程则完全相反。在切屑工具界面中发生扩散过程,导致切屑与切屑发生自阻塞。此外,还可以估计两种不同抗蠕变合金在切削过程中的发展温度。最后,理论结果与实验结果高度吻合。
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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