This paper uses ABAQUS software to simulate TI-6AL-4V cutting, mainly introduces cutting simulation and application, and puts forward the development prospect of finite element in cutting simulation direction.
Keywords: ABAQUS software; titanium alloy cutting simulation technology; cutting simulation direction
1. Constitutive model of cutting materials
Titanium alloys are widely used in the aerospace field because of their high strength, good corrosion resistance, and high heat resistance. Titanium alloys have good physical and mechanical properties, which are of great significance for mechanical structural parts with higher requirements. However, the machinability is poor, the processing is difficult, the processing cost is high, and the processing experiment will consume a lot of production time and cost. The ABAQUS / Explicit solver uses the explicit dynamic finite element method, which is suitable for short-lived and transient dynamic events such as impact and explosion. It is very effective for such highly nonlinear problems in the forming process. This thesis focuses on cutting TI-6AL-4V as an example for cutting simulation research.
2. Division of the grid
In the established finite element model, high-temperature and high-pressure elements are deformed in the shear zone and the blade-chip contact zone. Some elements may be distorted due to excessive deformation, which may distort the mesh or cause the calculation to not converge, even if the simulation is smooth Will affect the accuracy of the simulation. In order to prevent the above problems and ensure certain calculation efficiency and accuracy, the following measures can be taken:
- (1) The cutting layer mesh is denser because the cutting layer strain is larger.
- (2) Use dense to sparse grid division, which can not only ensure that part of the grid is directly cut, but also reduce the calculation time.
3. Simulation results
Chips are in line with the actual conditions, and are zigzag. According to different needs, different requirements can be output. According to the model and output variable settings, cutting force curve, cutting heat distribution map, cutting stress field cloud map, cutting strain field cloud map, etc.
4. Significance of cutting simulation
The cutting simulation results are closely related to the selected material model and parameters, grid division, contact settings, etc. The simulation ignores some factors such as cutting vibration, which makes the cutting simulation output results have certain differences from the actual, but with the development, Today’s cutting simulation has a certain accuracy. The use of finite element method in actual design or production can reduce the calculation and analysis time, reduce the number of experiments, so as to achieve the purpose of saving production costs and time. It has good practical significance for some improvements in cutting, such as optimization of tool angle, tool design and material selection.
5. Conclusion and Prospect
This article obtained the cutting simulation process by establishing the Johnson-Cook constitutive model and Johnson-Cook damage model of the material, and explained the application method of cutting simulation? W division, the simulated chip shape is basically consistent with the actual processing chip shape. With the development of science and technology, the finite element cutting simulation is being continuously improved, and now it has been used in actual machining analysis. In the future, the finite element cutting simulation will continue to develop to achieve the goal of being able to replace theoretical calculations and experimental experiments.