B-Area: Numerical Analyses of tool wear and surface integrity at machining Ti-6Al-4V

Person in Charge: Dr.-Ing. Frederik Zanger

Motivation and aim:
When machining metals high mechanical and thermal loads occur at the tools and the work pieces. These loads depend on the work piece material, process parameters (cutting velocity, cutting thickness) and geometry parameters of the tools (rake angle, flank angle, cutting edge radius). The thermal and mechanical loads cause changes of the tool geometry due to tool wear and influence the resulting surface integrity of the machined work pieces in terms of residual stresses. The surface integrity is furthermore influenced by the changed tool geometry, because the mechanical and thermal loads are inter-related to the subsequent tool geometries.

Approach

Results

Development of a holistic Finite-Element-Modell to predict surface integrity after machining under consideration of tool wear:

Numerical and experimental investigations of chip segmentation when machining Ti-6Al-4V
Examinations of tool wear behavior
Analytically and numerically modeling of tool wear
Surface Integrity characterization after machining

Thermal and mechanical loads are calculated reliably by the simulation model of machining Ti-6Al-4V
Tool wear simulations show good accordances with the experimentally achieved tool lifetimes.