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Numerical modelling of ti6A14V machining : a combinded FEA and unified mechanics of cutting approach

Bowes, David Christian (2013-03)

Thesis (MScEng)--Stellenbosch University, 2013.


ENGLISH ABSTRACT: In this study, Ti6Al4V machining is modelled using finite element analysis of orthogonal machining. Orthogonal turning tests are conducted for the verification of FE models in terms of machining forces, temperatures, and chip geometry. Milling force predictions are made using the "unified" mechanics of cutting model which is applied to ball nose milling for this study. The model makes use of orthogonal cutting data, collected from the turning tests, to model milling forces. Model predictions are compared with test data from slot milling tests for verification. Finally a hybrid form of the "‘unified"’ model is presented in which orthogonal data, obtained from the FE simulations, is used to model ball nose milling operations.

AFRIKAANSE OPSOMMING: In hierdie studie word titaanmasjinering (Ti6Al4V) gemodelleer deur gebruik te maak van eindige element analise van ortogonale masjinering. Ortogonale draai toetse word uitgevoer om eindige element (FE) modelle te verifieer in terme van masjineringskragte, temperatuur en spaandergeometrie. Freeskragte word voorspel deur gebruik te maak van die "Unified Mechanics of Cutting" model wat toegepas word op ’n balneusfrees operasie in hierdie studie. Die model maak gebruik van ortogonale snydata, versamel gedurende snytoetse, om die freeskragte te modelleer. Die model word vervolgens vergelyk met die toetsdata afkomstig van die freestoetse vir verifikasie. Ten slotte word ’n hibriede weergawe van die model aangebied waarin ortogonale data verkry word van die FE simulasie om balneus freesoperasies te simuleer.

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