Farshid Jafarian , Mohsen Bahrami , Mohammad Meghdad Fallah , Mohammad Malekan
{"title":"Numerical analysis of machinability and surface alterations in cryogenic machining of additively manufactured Ti6Al4V alloy","authors":"Farshid Jafarian , Mohsen Bahrami , Mohammad Meghdad Fallah , Mohammad Malekan","doi":"10.1016/j.simpat.2024.102961","DOIUrl":null,"url":null,"abstract":"<div><p>Metal additive manufacturing (AM) technology has been utilized in many industries including automotive, aerospace, and medical. AM Ti6Al4V (Ti64) alloy is highly noticed for production of medical instruments such as dental implants and the machining process is mostly needed during the production or post-processing of these components. Numerical model, as a powerful tool, can be efficiently used for analyzing the machining process. A customized model was employed using a user-written subroutine in this work to evaluate machinability and microstructural changes in cryogenic machining of AM Ti64 alloy. For this purpose, the microstructural changes were simulated as the new numerical outputs. The numerical results of cutting forces, temperature, nano-hardness, and alpha lamellae thickness (grain size) were successfully verified by corresponding experiments from literature. Then, the impact of tool geometry (including rake and clearance angles, cutting edge radius, and nose radius) on the machinability performance was examined. It was found that, the variation of clearance and rake angles were more effective on depth of the hardened layer compared to the other parameters. Thickness of alpha lamellae phase near the machined surface and depth of the affected layer by nano-hardness changes were changed from 0.9 to 1.58 µm, and from 18 to 40 µm, respectively. Overall, it was concluded that the variation of insert positioning made by tool holder (change in rake and clearance angles) was an effective parameter on the process outputs when machining AM Ti64 alloy.</p></div>","PeriodicalId":49518,"journal":{"name":"Simulation Modelling Practice and Theory","volume":"134 ","pages":"Article 102961"},"PeriodicalIF":3.5000,"publicationDate":"2024-05-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Simulation Modelling Practice and Theory","FirstCategoryId":"94","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S1569190X24000753","RegionNum":2,"RegionCategory":"计算机科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q2","JCRName":"COMPUTER SCIENCE, INTERDISCIPLINARY APPLICATIONS","Score":null,"Total":0}
引用次数: 0
Abstract
Metal additive manufacturing (AM) technology has been utilized in many industries including automotive, aerospace, and medical. AM Ti6Al4V (Ti64) alloy is highly noticed for production of medical instruments such as dental implants and the machining process is mostly needed during the production or post-processing of these components. Numerical model, as a powerful tool, can be efficiently used for analyzing the machining process. A customized model was employed using a user-written subroutine in this work to evaluate machinability and microstructural changes in cryogenic machining of AM Ti64 alloy. For this purpose, the microstructural changes were simulated as the new numerical outputs. The numerical results of cutting forces, temperature, nano-hardness, and alpha lamellae thickness (grain size) were successfully verified by corresponding experiments from literature. Then, the impact of tool geometry (including rake and clearance angles, cutting edge radius, and nose radius) on the machinability performance was examined. It was found that, the variation of clearance and rake angles were more effective on depth of the hardened layer compared to the other parameters. Thickness of alpha lamellae phase near the machined surface and depth of the affected layer by nano-hardness changes were changed from 0.9 to 1.58 µm, and from 18 to 40 µm, respectively. Overall, it was concluded that the variation of insert positioning made by tool holder (change in rake and clearance angles) was an effective parameter on the process outputs when machining AM Ti64 alloy.
期刊介绍:
The journal Simulation Modelling Practice and Theory provides a forum for original, high-quality papers dealing with any aspect of systems simulation and modelling.
The journal aims at being a reference and a powerful tool to all those professionally active and/or interested in the methods and applications of simulation. Submitted papers will be peer reviewed and must significantly contribute to modelling and simulation in general or use modelling and simulation in application areas.
Paper submission is solicited on:
• theoretical aspects of modelling and simulation including formal modelling, model-checking, random number generators, sensitivity analysis, variance reduction techniques, experimental design, meta-modelling, methods and algorithms for validation and verification, selection and comparison procedures etc.;
• methodology and application of modelling and simulation in any area, including computer systems, networks, real-time and embedded systems, mobile and intelligent agents, manufacturing and transportation systems, management, engineering, biomedical engineering, economics, ecology and environment, education, transaction handling, etc.;
• simulation languages and environments including those, specific to distributed computing, grid computing, high performance computers or computer networks, etc.;
• distributed and real-time simulation, simulation interoperability;
• tools for high performance computing simulation, including dedicated architectures and parallel computing.