Ali Moaz H
Department of Computer Engineering Techniques, AlSafwa University College, Karbala, Iraq.
Heliyon. 2023 Jun 27;9(7):e17670. doi: 10.1016/j.heliyon.2023.e17670. eCollection 2023 Jul.
Due to its qualities, There is a lot of use of the titanium alloy (Ti-6Al-4V) in gas turbines and other aero engines. It is difficult to determine machining parameters such cutting force, temperature, and surface roughness, and it is difficult to calculate these values using analytical methods. The finite element method (FEM) is a particularly useful platform for studies since it predicts the machining parameters.
The advantage of this method is taken for the purpose of linking the mechanical and thermal equations based on a step of the dynamic, temperature-displacement, explicit of the Lagrangian formulation in a new model that is fully thermomechanically connected. Three mesh areas were created for optimizing the cutting zone during the cutting simulation process. The machining process by using a face milling tests was carried out. There are two variable factors of cut such as feed rate, cutting speed are created randomly when depth is a constant parameter. High-speed camera used to capture the machining process which determines the important details of spark generated.
There is a very excellent agreement between the experimental data and the simulation results from the finite element modeling (FEM). By raising the feed rate in the cutting zone, the cutting temperature can be raised and a spark can be generated. This led to the conclusion that surface roughness trends can be predicted using feed cutting force measurements. Surface roughness rose in direct proportion to the magnitude of the feed cutting force, and vice versa.
由于其特性，钛合金（Ti-6Al-4V）在燃气轮机和其他航空发动机中有大量应用。确定诸如切削力、温度和表面粗糙度等加工参数很困难，并且使用解析方法计算这些值也很困难。有限元方法（FEM）是进行研究的一个特别有用的平台，因为它可以预测加工参数。
利用该方法的优势，基于拉格朗日公式的动态、温度-位移显式步骤，在一个完全热机械连接的新模型中关联机械方程和热方程。在切削模拟过程中创建了三个网格区域以优化切削区域。通过面铣试验进行加工过程。当切削深度为恒定参数时，随机创建进给速度和切削速度这两个切削变量因素。使用高速摄像机捕捉加工过程，以确定产生火花的重要细节。
实验数据与有限元建模（FEM）的模拟结果之间有非常好的一致性。通过提高切削区域的进给速度，可以提高切削温度并产生火花。由此得出结论，使用进给切削力测量可以预测表面粗糙度趋势。表面粗糙度与进给切削力的大小成正比增加，反之亦然。
