ScienceDirect. Prediction of Cutting Forces at 2D Titanium Machining

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Crotoru* Poltena Unversty, 313 Splaul Independente, Buarest RO 060042, Romana Astrat Te paper presents aspets related to smulaton for optmzaton of metal ttng for ttanum and ts alloys.

For smulatons, te software ased on fnte element metod - DEFORM 2D - was used. Cuttng proess smulatons were made for several materals, n te same ttng ondtons. Some of te otaned results are presented.

1 Avalale onlne at SeneDret Proeda Engneerng 69 ( t DAAAM Internatonal Symposum on Intellgent Manufaturng and Automaton, 2013 Predton of Cuttng Fores at 2D Ttanum Manng Dana Andreea Coron, Sorn Ma Crotoru* Poltena Unversty, 313 Splaul Independente, Buarest RO , Romana Astrat Te paper presents aspets related to smulaton for optmzaton of metal ttng for ttanum and ts alloys. Due to te orroson resstane, g meanal strengt and low densty, ttanum and ts alloys are rrently attratve materals n te ndustry. For smulatons, te software ased on fnte element metod - DEFORM 2D - was used. Cuttng proess smulatons were made for several materals, n te same ttng ondtons. Some of te otaned results are presented. Conlusons are presented n terms of omparson Te Autors. Pulsed y y Elsever Ltd. Ltd. Open aess under CC BY-NC-ND lense. Seleton and peer-revew under responslty of of DAAAM Internatonal Venna. Keywords: smulaton; ortogonal ttng; ttng fore; ttanum 1. Introduton Hstorally speakng, untl reently t was onsdered tat te ttng proess of ttanum and ts alloys would e dfflt. Wt te development of modern manufaturng metods and proesses, ttng tese alloys and also ter use n more and more areas of ndustral engneerng, eame nreasngly attratve. Nowadays, n w onerns manng proess, tere s a wdespread trend to use g ttng speeds - "Hg Speed Manng". Related to te ttng proess tere are two mportant elements: workpee and ttng tool. Also, oter elements sould e onsdered: tool lampng and workpee, ttng regme parameters and te use of oolng luraton lqud. Cuttng proesses requre g manufaturng aray, w also lead to a good qualty of te otaned surfaes. Surfae low qualty s strtly nfluened y ertan fators, su as napproprate oe of ttng regme parameters (v, f, a p, dynam eavour of te tenologal system, tool wear et. In metal ttng, due to layer y layer removal of te ps, a g dmensonal aray s otaned. * Correspondng autor. Tel.: ; fax: E-mal address: sorn.rotoru@gmal.om Te Autors. Pulsed y Elsever Ltd. Open aess under CC BY-NC-ND lense. Seleton and peer-revew under responslty of DAAAM Internatonal Venna do: /j.proeng

82 Dana Andreea Coron and Sorn Ma Crotoru / Proeda Engneerng 69 ( 2014 81 89 Under te aton of te ttng tool edge, te addtonal materal of te workpee turns to ps.

2 82 Dana Andreea Coron and Sorn Ma Crotoru / Proeda Engneerng 69 ( Under te aton of te ttng tool edge, te addtonal materal of te workpee turns to ps. In te workpee zone of p formaton te dstruton of ompresson stress and frton wll nfluene te ttng fores tat or durng te proess. To see tese nfluenes and to predt ttng fores n ttng ttanum and ts alloys, spealzed software DEFORM 2D was used to smulate ortogonal ttng [1]. Te software uses te fnte element metod for modellng te dynams of pure plast or elast-plast deformaton proesses. Te teory of metal ttng proesses and penomena are explaned y plast deformaton of te workpee materal, so te ttng proess tself s a plast deformaton proess. Tus, we an say tat onventonal manufaturng of metals an e made troug plast deformaton proesses. In DEFORM 2D smulaton ot tool and workpee an e defned n te software. Te nremental movement of te atve part of te ttng tool s smulated and, f neessary, te software remodels te mes automatally and allatons are ontnued [1, 2, 3]. It sould e mentoned tat te software redues smulaton prolem n a plane, w s possle for ortogonal ttng. For omplex surfaes t s reommended to use DEFORM 3D software. However, onsderng te proessng tme allatons, w for DEFORM 2D an take tens of mnutes and for DEFORM 3D an take tens of ours (dependng on te omplexty of te model and te apaltes of te omputer, t s reommended tat te set of ttng ondtons sould e made n DEFORM 2D and omplex smulaton model sould e made n DEFORM 3D. 2. Smulaton of ttng proess Tere were performed several sets of smulatons on two grades of pure ttanum (grade 1 and grade 2 and for one of ts alloys, T6Al4V, onsdered as te referene ttanum alloy. Te elastty of workpee materals was not onsdered n te smulatons eause metal ttng s a proess w takes plae n te plast feld, even f elast deformatons or. Te measurement unts were onsdered n te Internatonal System, ut t an e also used te Engls System [1]. Fg. 1. Smulaton of workpee lampng for studed ases y means of order ondtons [1]. From te egnnng, DEFORM 2D software sets te ondtons for smulaton, su as: proess type, geometry, temperature and materals of ot workpee and ttng tool, workpee mes omplexty, ttng tool relatve movement to te workpee, wlst te workpee s fxed y means of mposed oundary ondtons (see fgure 1 or y means of a lampng deve, onsdered as te seond de. In proessng pure and alloyed ttanum, due to small ttng speeds, te way to nrease produtvty s y nreasng te dept of t. Generally speakng, te rougng of pure and alloyed ttanum uses speeds of 60 m/mn, and fnsng operatons are performed at speeds up to 250 m/mn.

Dana Andreea Coron and Sorn Ma Crotoru / Proeda Engneerng 69 ( 2014 81 89 83 Fg. 2. Te nfluene of ttng parameters varaton upon tool duralty [4].

3 Dana Andreea Coron and Sorn Ma Crotoru / Proeda Engneerng 69 ( Fg. 2. Te nfluene of ttng parameters varaton upon tool duralty [4]. Wen manng ttanum and ts alloys, n order to remove exess eat tat ors at te ontat etween ttng tool and workpee, and also to remove te ps formed n te proess of metal ttng, t s gly reommended to use oolng lqud. Ts means to onsder proper frton oeffent and temperature n te proess. Cuttng tools used must meet ertan ondtons for manufaturng, see fgure 2 [4], eause resulted ps are ardened, w an lead to premature wear of tese tools. Beause of te tool duralty, manufaturng ttanum s dretly nfluened y temperature of te ttng edge. Te orret oe of ttng regme s a alane etween ttng speed and p dmensons (dept of t and feed.[3] As mentoned aove, under te aton of te tool edge, te addtonal materal of te workpee turns to ps. In te zone of p formaton ors a state of stress, related to te ttng regme nput and output parameters. Cuttng fores are omponents of total ttng resstane R on te tree axes of OXYZ knemat referene system [5]: Fore Fz s te man ttng fore, Fore Fx s te feedng fore, Fore Fy s te rejeton fore. Determnaton of ttng fores was te ojet of many researes, analytal expressons for ter determnaton wt dfferent forms: exponental, polynomal et., onsderng varous parameters of te ttng ondtons. Dependng on a very large numer of parameters, ttng fores an araterze a workpee materal from te pont of vew of ttng manalty. Forms of analytal relatonsps for determnng te ttng fores are sown elow, n an exeptonal revew [5]. Smple models - Lnear Funtons J.Hart (1876; H.Fser (1897 F = K (1 1 H.Fredr (1909 F = K q+w (2 1 R s

4 84 Dana Andreea Coron and Sorn Ma Crotoru / Proeda Engneerng 69 ( A.Rter (1954 F = C1 +C2 (3 Smple models Exponental Funtons F.W.Taylor (1907 F = K t K2 s (4 1 C.Salomon (1928 F 1 (x+ = K (5 O.Kenzle (1951 F = K 1.1 H.Vktor (1956 (1-m (6 F = f (1-m K 1.l (7 M.Hrsfeld (1953 F j = (1-m K 1.1j L.Deselaers (1970 (8 F s = C (1-m K 1.1 (9 H.Kamm (1977 F K = = K 0 + K 1 ( 1 -Ck (10 K.Langammer (1972 F -m = (1-x K HV100 HV ( 100 v ( 100 (11

5 Dana Andreea Coron and Sorn Ma Crotoru / Proeda Engneerng 69 ( Smple models - Comned Funtons U.Klpera (1972 F q = p + g + e (12 W.Engelard (1976 F q 1 = p ( m m + g + e k e e (13 Complex models - empral W.Klen (1937 F = (g(mat.pesa+ f(mat.pesa, (1+ tg (14 _ H.Brandenerger (1945 F = q zef (15 F.Eksten (1973 F = zef (16 Complex models - teoretal H.Hus (1951 F = 0 (17 K.F.Meyer (1965 F = F d + ; = - (18 tg tg L.Kaznzy (1974 F S s s 1 = t B ;F = t B (19 sn sn o os45 Tese relatonsps were determned analytally, ut are ased and ompleted y expermental resear. Bak n te late 1970 s, Professor Stefanuta Enae from Unversty Poltena of Buarest, memer of CIRP at te tme, used a very smple relatonsp to determne te ttng fore: F = ( f a (20 r p

86 Dana Andreea Coron and Sorn Ma Crotoru / Proeda Engneerng 69 ( 2014 81 89 were σr tensle strengt of te workpee materal, f feed and a p ttng dept, mnmum ttng fore oeffent = 3 for g strengt (dutle

6 86 Dana Andreea Coron and Sorn Ma Crotoru / Proeda Engneerng 69 ( were σr tensle strengt of te workpee materal, f feed and a p ttng dept, mnmum ttng fore oeffent = 3 for g strengt (dutle materals (steel, maxmum ttng fore oeffent = 7 for low strengt (fragle materals (ast ron[6]. Equaton (20 s very useful, onsderng ts smplty and te sgnfant errors of Taylor s pratal equatons. Cuttng dept s an mportant ttng parameter w nfluenes te ttng fores, wen all te oters are kept dental. Wen ttng dept s very small ttng pressure s very g, leadng to te rse of te ttng fores. In ts ase a smlar relatonsp to equaton (20 an e used, te values of te ttng fore oeffent eng 2 5 for tents of mllmeters up to 5 10 for undredts of mllmeters [6]. Cuttng fores are an mportant part of te ttng proess and are nfluened y almost all system parameters: atve part materal for te ttng tool, manng proess, workpee materal, ttng regme parameters, atve part geometry for te ttng tool, manufaturng envronment ondtons, ttng fluds, ttng tool wear ondton [3]. Usng DEFORM 2D software te predton of ttng fores was smulated, onsderng mposed parameters of te ttng regme. For ortogonal ttng smulaton, only te ttng speed and dept were used. In order to smulate te proess, te followng data were osen: ttng speed 60 m/mn, ttng dept 1 mm and te tool rake angle γ = 5. a Fg. 3. Te state of stran durng te smulaton for te tree studed ases. a Fg. 4. Te state of effetve stress for te tree studed ases.

Dana Andreea Coron and Sorn Ma Crotoru / Proeda Engneerng 69 ( 2014 81 89 87 Te studed workpee materals were ttanum alloy (T6Al4V and two grades of pure ttanum (1 and 2, wt propertes defned n te

Te smulaton nluded te followng steps: namng te studed prolem (fle, settng te load ase (symmetral / asymmetral to redue te ase to a 2D prolem, settng te workpee geometry, mesng te geometral model, oe

7 Dana Andreea Coron and Sorn Ma Crotoru / Proeda Engneerng 69 ( Te studed workpee materals were ttanum alloy (T6Al4V and two grades of pure ttanum (1 and 2, wt propertes defned n te lrary of materals found n DEFORM 2D software. Te smulaton nluded te followng steps: namng te studed prolem (fle, settng te load ase (symmetral / asymmetral to redue te ase to a 2D prolem, settng te workpee geometry, mesng te geometral model, oe of te workpee materal, settng te oundary ondtons, settng te ttng tool geometry and, eventually, te lampng deve of te workpee, relatve postonng elements, dataase generaton, run of te smulaton, vsualzaton of results n pre- and post-proessor [3]. a Fg. 5. Te state of temperature for te tree studed ases. In te ptures, tere are sown te ompared results otaned from smulatons for all tree types of materals mentoned (a s T6Al4V, T grade 1, T grade 2, n terms of effetve stran (Fg. 3, effetve stress (Fg. 4 and temperature (Fg. 5. Beng rtera to evaluate ttng manalty of workpee materals, t s nterestng to menton te values otaned y smulaton for effetve stran (Fg. 3, effetve stress (Fg. 4 and temperature (Fg. 5, see tale 1 (maxmum values. Generally speakng, t s ovous tat derease of te purty of ttanum leads to te nrease of ttng stress and temperature and derease of stran. Same trend s oserved for tensle strengt of te same materals, see tale 2. By means of ts post proessor, DEFORM 2D provdes a seres of omplex evaluatons (output data, nludng predton of fores. All measurement unts used n te program were onsdered n te nternatonal system. Te software offers output data nformaton vs. tme/stroke on X and Y axes, and a step y step vdeo proess of ttng. Fgure 6 presents te predton of ttng fore along X axs for all tree types of materals osen. It sould e mentoned tat tere s a relatonsp etween te ttng fore and te rake angle, meanng tat wt nrease of te rake angle, te ttng fores derease. Te state of effetve stress produed n te p durng smulaton of metal ttng proess dereases wt te nrease of te rake angle [3].

88 Dana Andreea Coron and Sorn Ma Crotoru / Proeda Engneerng 69 ( 2014 81 89 Tale 1. Smulaton results. Materal Maxmum eff. stran [mm/mm] Maxmum eff. stress [MPa] T6Al4V 3.44 1890 1590 T gr. 1 3.

Meanal propertes Ttanum grade 1 Ttanum grade 2 Alloy T6Al4V Tensle strengt, [Mpa] 240 345 1000 Yeld strengt, [Mpa] 170 275 110 Elongaton, [%] 24 20 15 Area reduton, [%] 30 30 20 Max.

By omparson, related to professor Enae s formula, tale 2 [7,8] sows tat te more mpure ttanum s, te greater strengt t as and te less value of te ttng fore oeffent ors.

8 88 Dana Andreea Coron and Sorn Ma Crotoru / Proeda Engneerng 69 ( Tale 1. Smulaton results. Materal Maxmum eff. stran [mm/mm] Maxmum eff. stress [MPa] T6Al4V T gr T gr Maxmum ttng temperature [ºC] Tale 2. Meanal propertes of pure ttanum grade 1 and 2 and ttanum alloy T6Al4V [7, 8], ompared to smulated spef ttng fore. Meanal propertes Ttanum grade 1 Ttanum grade 2 Alloy T6Al4V Tensle strengt, [Mpa] Yeld strengt, [Mpa] Elongaton, [%] Area reduton, [%] Max. smulated spef ttng fore, [N] Max. spef ttng fore / tensle strengt Fgure 6 presents te predted ttng fore gven y te post-proessor of DEFORM 2D. By omparson, related to professor Enae s formula, tale 2 [7,8] sows tat te more mpure ttanum s, te greater strengt t as and te less value of te ttng fore oeffent ors. Maxmum value of te effetve stress orred n ontat area, for ea ase, s losed to strengt tensle value for ea materal multpled y professor Enae s ttng fore oeffent (3 7. Of ourse, te ttng dept was osen n te range of tents of mllmeter, so te ttng fore oeffent n equaton (20 elongs to te lower values, as presented. Fnally, an empr formula ould e used to determne ttng fore n pratal ases: F = ( f a, (21 r p eng very smlar to professor s Enae formula, te lower value of ttng fore oeffent eng used for g strengt materals and ttng depts of tents of mllmeter and even ger, ttng fore oeffent value s eng used for low strengt materals and ttng depts of undredts of mllmeter. a Fg. 6. Predton of ttng fores along X axs.

9 Dana Andreea Coron and Sorn Ma Crotoru / Proeda Engneerng 69 ( Beause of su varaton of te ttng fore t s ovous wy determnaton of Taylor s ttng fore formula s made only on small range values of te ttng regme parameters. Stll, t s performed expermentally, wt ost and tme onsumpton, w justfes te proposed equaton ( Conluson DEFORM 2D provdes ortogonal ttng or 2D plast deformaton proesses smulaton results. In ts paper smulatons were performed to oserve te ttng fores n pure ttanum (grade 1 and grade 2 and ttanum alloy (T6Al4V ttng proess araterzaton. Smulated ttng fores n DEFORM 2D are spef ttng fores, meanng ttng fore per mllmeter of edge, otaned n ortogonal ttng. In real ases (even ortogonal or omplex ttng ttng fores are greater, eng proposed an empr formula (21, dependng of te tenologal parameters of te p area. Te maxmum value of spef man ttng fore s equal to te tensle strengt of te materal, multpled y tenologal area of te p (feed x dept of t and a ttng fore oeffent (see equaton 21. Professor Enae s formula stated a range of ttng fore oeffents onsderng medum ttng depts. In real ttng proesses very small values of te ttng dept or (undredts of mllmeter. In tese ases te ttng fore nreases for approxmately 2 tmes. Ts s related to te p deformaton proess. It s well known tat values of te ttng dept under 0.01 mm are not possle, eause n ts ase ttng proess (p removal s replaed y plast deformaton proess. Ts paper stated tat te ttng fore oeffent nreases wt te derease of te ttng dept, te lower value of ttng fore oeffent eng used for g strengt materals and ttng dept of tents of mllmeter and ger value of ttng fore oeffent eng used for low strengt materals and ttng dept of undredts of mllmeter. It an also e stated te ttng fore oeffent nreases wt te derease of one tenologal parameter of te p, eter ttng dept or feed[9]. Comparng te empr formula (21 to Taylor s equaton t an e stated ts empr formula s smpler and t an e used n pratal ases. Even wen a Taylor s equaton s expermentally determned, t as errors, and t s determned for a spef range of ttng parameters values[10] Also, te smulatons were made to otan oter output data, lke effetve stran, effetve stress and ttng temperature, w are evaluaton rtera of workpee materal manalty. It was prevously found [2, 3] tat tere s a relatonsp etween ttng fores and tool rake angle varaton, meanng tat te optmum value of rake angle leads to an nrease of ttng manalty and n te same tme, to a derease of te ttng fores. Te smulaton of ttng and deformaton proesses usng DEFORM software an lead to optmum ttng / deformaton proess ondtons related to ttng ttanum and ts alloys, as well as oter workpee materals, otanng parts n optmal ondtons. It s ovous te optmzaton y smulatons as advantages, avodng tme and ost onsumpton w would or n performng real experments. Stll, tere are dsadvantages, lke software osts and te need for valdaton n te real lfe. Of ourse, ts valdaton ould e done only n some ases, not for all planned experments. Refferenes [1] ***, DEFORM 2D perpetual lense, enefary: POLITEHNICA Unversty of Buarest, Natonal Center for Tenologal Systems Performanes Resear OPTIMUM. [2] S. M. Crotoru, G. Constantn, Smulaton of Ttanum Parts Manufaturng, Proeedngs of te 1-st WSEAS Internatonal Conferene on VISUALIZATION, IMAGING and SIMULATION (VIS'08, 2008, ISBN: , pg [3] D.A. Coron, Prelurarea mplanturlor dentare dn ttan s alajele sale (Manufaturng of Dental Implants Made of Ttanum and Its Alloys, Dssertaton Paper, Mane and Manufaturng Systems Department, Unversty Poltena of Buarest, Romana, [4] ttp:// [5] B. Coldng, W. Kong, Valdty of te Taylor Eaton n Metal Cutng Tool, Annals of CIRP, Vol. XVIV, [6] A. Oprean, et al., Bazele aser s generar suprafetelor (Bass of Surfaes Cuttng and Generaton, EDP, Buarest, Romana, 1981 [7] ttp:// Standards Woldwde, Aessed on: [8] ttp://en.wkpeda.org/wk/ttanum, Aessed on: [9] M. Dogra, V. S. Sarma, J. Dureja, Effet of tool geometry varaton on fns turnng A Revew, Journal of Engneerng Sene and Tenology, 2011, Volume 4, Issue 1, ISSN: , pg [10] H.M. Zeqr, N.E. Qeaja, F. Zeqr, A.H. Salu, H. Osman, Resear of flank wear n turnng of steel CK60, Annals of DAAAM for 2012 & Proeedngs of te 23rd Internatonal DAAAM Symposum, Volume 23, No.1, ISSN , ISBN , pg

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