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Simulation research on the grinding forces and stresses distribution in single-grain surface grinding of Ti-6Al-4V alloy when considering the actual cutting-depth variation

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Abstract

A finite element model of single-grain surface grinding of Ti-6Al-4V titanium alloy has been established, which takes into consideration of the actual variation of cutting depth along the grinding path. The effects of both the grinding speed and actual cutting depth on the grinding forces and stresses distribution were analyzed. Formation of the discontinuous lamellar structure chips in single-grain surface grinding was simulated. Based on the critical thickness of chip formation, a critical grinding speed, such as 60 m/s, is determined. The critical thickness of chip formation decreases with increasing the grinding speeds between 20 and 60 m/s; on the contrary, the critical thickness of chip formation increases with increasing the grinding speeds between 60 and 200 m/s. In one grinding periodic, the peak values of grinding force curves firstly increase gradually and then decrease sharply. When the uncut chip thickness is 0.7 μm, the maximum principal stress is obtained at the actual cutting depth of 0.6 μm. The largest tensile stress is always produced at grain rake face relative to the grain tip.

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Authors and Affiliations

  1. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, 210016, People’s Republic of China

    Dengkui Fu, Wenfeng Ding, Qing Miao & Jiuhua Xu

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  1. Dengkui Fu
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  2. Wenfeng Ding
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  3. Qing Miao
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  4. Jiuhua Xu
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Correspondence to Wenfeng Ding.

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Fu, D., Ding, W., Miao, Q. et al. Simulation research on the grinding forces and stresses distribution in single-grain surface grinding of Ti-6Al-4V alloy when considering the actual cutting-depth variation. Int J Adv Manuf Technol 91, 3591–3602 (2017). https://doi.org/10.1007/s00170-017-0084-9

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  • DOI: https://doi.org/10.1007/s00170-017-0084-9

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