CHIP MORPHOLOGY WITH FINITTE ELEMENT SIMULATIONS IN HIGH SPEED TURNING OF 7075-T6 ALUMINUM ALLOY

Brant Liou 12/15/2005

Why Study Chip Morphology

In order to develop new cutting processes - chip formation affects every aspects

of high speed machining processes, such as machining dynamics affected by chip forms

Improve tool life -

tool-wear and tool life

Theories for chip formation in high speed machining

Shear instability theory R. H. Brown and R. Komanduri suggested that chip serration is caused by a periodic catastrophic thermoplastic instability where the decrease in material flow stress due to thermal softening more than offsets the associated strain hardening.

Crack initiation and growth theory

Nakayama suggested that chip serration is caused by crack initiation, growth, and failure. The ductility or the ultimate shear strain of the material to be cut and the normal stress on the shear plan are the two root causes of crack initiation. Coldworking and heat treatment plays an important role in material brittleness besides its chemical composition

Chip Types
Continuous chips - non-oscillatory Segmented chips - that is a chip in which shear zones appears periodically and chip thickness varies with time Discontinuous chips - it is formed when chip segmentation increases to the point where each segment breaks.

Chip Types

Chip Types

Continuous Chip

Segmented Chip

Analytical Predictive Modeling of Chip Formation

hchmax = lAD * cos ( -AD ) hchmin = lBC * cos (BC - ) Ds = ( hchmax - hchmin ) / hchmax

Comparisons of Analytical Predictive Model and Finite Element Simulations (Cutting Speed)
Workpiece material = Al 7075 T6 Feed = 0.2 mm/rev Speed =1000 - 5000 m/min Rake Angle = 5 5 Cutting Radius = 0.02 mm Workpiece material = Al 7075 T6 Depth of Cut = 4 mm Feed = 0.2 mm/rev Speed = 1000 m/min Rake Angle = 5 5 Cutting Radius = 0.02 mm Relief Angle = 10 10 Cutting Tool Carbide General

Comparisons of Analytical Predictive Models and Finite Element Simulations (Cutting Speed)
Workpiece material = Al 7075 T6 Depth of Cut = 4 mm Feed = 0.2 mm/rev Speed = 3000 m/min Rake Angle = 5 5 Cutting Radius = 0.02 mm Relief Angle = 10 10 Cutting Tool Carbide General Workpiece material = Al 7075 T6 Depth of Cut = 4 mm Feed = 0.2 mm/rev Speed = 5000 m/min Rake Angle = 5 5 Cutting Radius = 0.02 mm Relief Angle = 10 10 Cutting Tool Carbide General

Comparisons of Analytical Predictive Model and Finite Element Simulations ( Feed)

Workpiece material = Al 7075 T6 Feed = 0.05 0.25 mm/rev Speed =1000 - 5000 m/min Rake Angle = 5 5 Cutting Radius = 0.02 mm Workpiece material = Al 7075 T6 Depth of Cut = 4 mm Feed = 0.05 mm/rev Speed = 4000 m/min Rake Angle = 5 5 Cutting Radius = 0.02 mm Relief Angle = 10 10 Cutting Tool Carbide General

Comparisons of Analytical Predictive Model and Finite Element Simulations ( Feed)

Workpiece material = Al 7075 T6 Depth of Cut = 4 mm Feed = 0.15 mm/rev Speed = 4000 m/min Rake Angle = 5 5 Cutting Radius = 0.02 mm Relief Angle = 10 10 Cutting Tool Carbide General Workpiece material = Al 7075 T6 Depth of Cut = 4 mm Feed = 0.25 mm/rev Speed = 4000 m/min Rake Angle = 5 5 Cutting Radius = 0.02 mm Relief Angle = 10 10 Cutting Tool Carbide General

Comparisons of Analytical Predictive Model and Finite Element Simulations ( Tool Rake Angle)
Workpiece material = Al 7075 T6 Feed = 0.05 0.25 mm/rev Speed =1000 - 5000 m/min Rake Angle = 10 ~ -10 10 10 Cutting Radius = 0.02 mm Workpiece material = Al 7075 T6 Depth of Cut = 4 mm Feed = 0.25 mm/rev Speed = 4000 m/min Rake Angle = 5 5 Cutting Radius = 0.02 mm Relief Angle = 10 10 Cutting Tool Carbide General

Comparisons of Analytical Predictive Model and Finite Element Simulations ( Tool Rake Angle)
Workpiece material = Al 7075 T6 Depth of Cut = 4 mm Feed = 0.25 mm/rev Speed = 4000 m/min Rake Angle = 0 0 Cutting Radius = 0.02 mm Relief Angle = 10 10 Cutting Tool Carbide General Workpiece material = Al 7075 T6 Depth of Cut = 4 mm Feed = 0.25 mm/rev Speed = 4000 m/min Rake Angle = -5 Cutting Radius = 0.02 mm Relief Angle = 10 10 Cutting Tool Carbide General

Conclusions and Summaries

Both the maximum and minimum chip thickness hchmax, hchmin increase with decreasing cutting speed V, increasing undeformed chip thickness (feed) hc, and decreasing rake angle . The pitch of the serrated chip P increases with decreasing cutting speed V, increasing undeformed chip thickness (feed) hc, and decreasing rake angle .

Conclusions and Summaries

Ds increases with decreasing cutting speed. Ds increases with increasing undeformed chip thickness. Ds increases with decreasing tool rake angle.

Conclusions and Summaries

Among the three influencing cutting conditions, the cutting speed is the relatively least important in affecting Ds. Cutting speed is the first important factor in affecting the initiation of a serrated chip (need high cutting speed to initiate the formation of serrated chip). Once the serrated chip is formed, the cutting speed become secondary factor The undeformed chip thickness is the most important factor in affecting Ds once a serrated chip is formed in high speed machining.

Conclusions and Summaries

The cutting forces Fc and the thrust force Ft increases with decreasing V, increasing f, , and decreasing

References

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