FEM Simulation Of Milling Tool Wear For Titaninum Alloys TC4

Titanium alloys have the characteristics of high strength, excellent corrosion resistance, good heat resistance, so they have been widely used in various fields, especially in the aerospace industry. However, they are difficult to machine due to their poor thermal conductivity, high chemical activation and low elastic. In the metal cutting process, titanium alloy is easy to produce high temperature, accelerating tool wear. It is difficult to control the quality of machined surface and precision of titanium alloy workpiece. Metal cutting process is a complex large deformation, strain rate and coupled thermal-mechanical process, it is difficult to quantitatively analyze cutting mechanism with using the traditional method.. Modeling and simulation with finite element method (FEM) have the potential advantage for the research of tool wear. FEM is gradually becoming one of effective methods to simulate and research the metal cutting processes.In this thesis, titanium alloy TC4machining with using end milling cutter is simulated by FEM. Deform-3D is used to establish the three-dimensional end milling model of TC4alloy. Johnson-Cook constitutive model and Normalized Cockroft&Latham fracture criterion are applied for they fit high temperature, large deformation and large strain rate analysis. Custom of friction model, chip separation criteria and adiabatic shear model are used to simulate the cutting temperature and the process of tool wear, and then compare with the actual temperature and tool wear in milling experiment, it shows that the experiment and simulation results match very well. So using Deform-3D can well simulate the milling process, which can provide the basis for determining optimal milling parameters.