Experimental and Finite Element Simulation of Milling Process for γ-TiAl Intermetallics

doi:10.11900/0412.1961.2016.00256

Acta Metall Sin

2017, Vol. 53

Issue (4): 505-512 DOI: 10.11900/0412.1961.2016.00256

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Experimental and Finite Element Simulation of Milling Process for γ-TiAl Intermetallics

Li ZHOU^1,²,Chao CUI¹,Qing JIA²(

),Yingshi MA¹

1 School of Mechanical Engineering, Shenyang Ligong University, Shenyang 110159, China
2 Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China

Cite this article:

Li ZHOU,Chao CUI,Qing JIA,Yingshi MA. Experimental and Finite Element Simulation of Milling Process for γ-TiAl Intermetallics. Acta Metall Sin, 2017, 53(4): 505-512.

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Abstract

γ-TiAl intermetallics are attractive candidates for applications in aircraft turbine engines due to their low density and good mechanical properties at high temperature. However, the low room temperature ductility makes the machinability of these materials poorer compared to the conventional alloys. In this work, a meso-model of γ-TiAl intermetallic was developed using ABAQUS finite element software. The surface morphology and edge fracture mechanism of different material models were analyzed, and the effects of cutting parameters on the surface roughness and size of edge fracture were investigated. The results indicate that the cracks and pits occur between the lamellar and lamellar with different material properties. At the same time, due to the low ductility of γ-TiAl intermetallic, the negative shear angle begins to form at the exit of workpiece, then the edge fracture is formed. In addition, for both surface roughness and size of edge fracture, the experimental data are slightly higher than the simulated data obtained by the hexagonal lamellar model, and smaller than those obtained by the rectangular lamellar model. With the increasing of cutting depth, the surface roughness and the size of edge fracture increase gradually, on the contrary, the cutting speed has a small effect on them. Therefore, in order to obtain a fine surface quality during machining of γ-TiAl intermetallic, the cutting speed can be adopted as higher as possible, but not the cutting depth.

Key words: γ-TiAl intermetallics milling process meso-model finite element

Received: 23 June 2016

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	Li ZHOU
	Chao CUI
	Qing JIA
	Yingshi MA

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https://www.ams.org.cn/EN/10.11900/0412.1961.2016.00256 OR https://www.ams.org.cn/EN/Y2017/V53/I4/505

Fig.1 OM image of γ-TiAl intermetallics

Fig.2 Illustration of flat-end milling process (v_f—feed rate, ω—rotation speed)

Fig.3 2D milling model of single tooth (r—radius of milling cutter, f_z—feed per tooth)

Fig.4 Two-dimensional finite element model of γ-TiAl intermetallics (a) and local zooming of Fig.4a (b) (h—effective cutting depth, RP—reference point)

Fig.5 FEM models of hexagonal (a) and rectangular (b) lamellae, which is composed of 0°, 45°, 90° and fully lamellar microstructures

Fig.6 Low (a, b) and locally high (c, d) magnified surface morphologies of γ-TiAl intermetallics obtained from hexagonal meso-model (a, c) and rectangular meso-model (b, d)

Fig.7 Section (a) and surface (b) OM images of γ-TiAl intermetallics after milling

Fig.8 Influences of cutting depth (a) and cutting speed (b) on surface roughness R_a

Table 1 Physical properties of different lamellar structures of γ-TiAl intermetallics^[5~12,25]

Fig.9 Edge morphologies on the exit surface of γ-TiAl intermetallics obtained from hexagonal meso-model (a, c) and rectangular meso-model (b, d) before (a, b) and after (c, d) fracture

Fig.10 SEM image of γ-TiAl intermetallics

Fig.11 Edge OM image of γ-TiAl intermetallics after milling

Fig.12 Influences of cutting depth (a) and cutting speed (b) on size of edge fracture W

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