Optimizing high speed end-milling of titanium alloy using mechanistic model, FEA and experimental design techniques

Author

Sandeep R. Aramalla

Abstract

"This thesis presents the results of modeling cutting forces, residual stresses and peak tool temperature in High-speed end-milling of titanium (Ti-6Al-4V) alloys. Three different approaches namely: Finite element analysis, mechanistic model and experimental verification were used for modeling and simulating cutting forces. Finite element analysis was used to model and simulate residual stresses and peak tool temperature. Finite element modeling and simulations were performed using Thirdwave AdvantEdge software using carbide end-mills with varying comer radius, coated with TiAlN. The effects of spindle speed, feed per tooth, axial and radial depth of cut, and corner radius on cutting forces, residual stresses and peak tool temperature were investigated using Taguchi Ll6 and Circumscribed Central Composite (27 runs) design of experiment. Mechanistic models of cutting forces for the same tool were developed and cutting forces predicted from this model were compared with those obtained from the finite element analysis. End-milling experiments were conducted on Cincinnati Milacron Sabre 750 Vertical Machining Center for determining the specific cutting and edge coefficients needed for mechanistic models and for validating the results obtained by the above two methods. Cutting forces were acquired using Kistler 4-component dynamometer. The results and optimum machining parameters for machining titanium in order to minimize cutting forces, residual stresses and peak tool temperature are presented. Cutting force results from mechanistic models are very much in agreement with those from experiment while those from FEA are in agreement only with the cutting force component in X and Y direction"--Abstract, page iv.

Advisor(s)

Okafor, A. Chukwujekwu (Anthony Chukwujekwu)

Committee Member(s)

Chandrashekhara, K.
Bekker, Miron

Department(s)

Mechanical and Aerospace Engineering

Degree Name

M.S. in Mechanical Engineering

Sponsor(s)

United States. Department of the Air Force

Publisher

University of Missouri--Rolla

Publication Date

Summer 2006

Journal article titles appearing in thesis/dissertation

• Modeling, simulation and optimization of cutting forces in high speed end-milling of titanium alloy using mechanistic modeling, finite element analysis and Taguchi design of experiment techniques
• Modeling, simulation and optimization of cutting forces in high speed end-milling of titanium alloy using mechanistic modeling, finite element analysis and central composite design of experiment techniques
• Modeling, simulation and optimization of residual stresses and temperature in high speed end-milling of titanium alloy using mechanistic modeling, finite element analysis and central composite design of experiment techniques

Pagination

xii, 140 pages

Note about bibliography

Includes bibliographical references (pages 116-117)

Rights

© 2006 Sandeep Reddy Aramalla, All rights reserved.

Document Type

Thesis - Restricted Access

File Type

text

Language

English

Subject Headings

Machining -- Evaluation
Milling (Metal-work) -- Evaluation
Titanium alloys -- Machinability

Thesis Number

T 9030

Print OCLC #

85863554

Recommended Citation

Aramalla, Sandeep R., "Optimizing high speed end-milling of titanium alloy using mechanistic model, FEA and experimental design techniques" (2006). Masters Theses. 3976.
https://scholarsmine.mst.edu/masters_theses/3976