Titanium alloys are widely used in various industries due to their superior characteristics such as high strength-to-weight ratio, toughness, corrosion resistance and bio-compatibility. Ti-6Al-4V is the most commonly used titanium alloy and considered as difficult-to-cut because of its low thermal conductivity, high chemical reactivity with cutting tool materials at elevated temperatures, and low modulus of elasticity. Therefore, rapid tool wear and poor surface quality are the issues in machining of this alloy. Hence, selecting appropriate cutting conditions (cutting speed, uncut chip thickness, depth of cut, etc.), tool materials, coatings, and geometry are essential not only to increase productivity and decrease the costs, but also to obtain a desirable surface integrity. Initially, a modified constitutive model was proposed for Ti-6Al-4V which is able to predict the behavior under high strains and temperatures. Since workpiece experiences high strain, strain rate at elevated temperatures during machining, it is important to develop a material model that captures material behavior at these conditions. Using this material model, two dimensional finite element simulations were designed to predict machining forces and serrated chip geometry and results were validated with experiments. This verified material model was used in three dimensional finite element simulations to predict tool wear, temperature, stress and strain distributions. Effects of different cutting tool materials, coatings (TiAlN and cBN), geometry and machining process parameters were investigated. A reliability model for different types of cutting tools is created with experimental and physics-based data. Furthermore, using genetic algorithms, a multi-objective optimization problem was designed and solved to find the optimal process parameters (cutting speed and feed) and cutting tool selection in order to maximize reliability and machining efficiency. Finally, validation experiments were conducted to measure tool wear on uncoated and TiAlN coated inserts under the optimum cutting conditions with expected reliability rating. The results indicate that there is an adequate agreement and the discrepancy may be related to model uncertainty and stochastic nature of the tool wear.
Subject (authority = RUETD)
Topic
Industrial and Systems Engineering
RelatedItem (type = host)
TitleInfo
Title
Rutgers University Electronic Theses and Dissertations
Identifier (type = RULIB)
ETD
Identifier
ETD_6386
PhysicalDescription
Form (authority = gmd)
electronic resource
InternetMediaType
application/pdf
InternetMediaType
text/xml
Extent
1 online resource (xx, 257 p. : ill.)
Note (type = degree)
Ph.D.
Note (type = bibliography)
Includes bibliographical references
Subject (authority = ETD-LCSH)
Topic
Finite element method
Subject (authority = ETD-LCSH)
Topic
Structural analysis (Engineering)
Subject (authority = ETD-LCSH)
Topic
Cutting machines
Note (type = statement of responsibility)
by Mohammad Sima
RelatedItem (type = host)
TitleInfo
Title
Graduate School - New Brunswick Electronic Theses and Dissertations
Identifier (type = local)
rucore19991600001
Location
PhysicalLocation (authority = marcorg); (displayLabel = Rutgers, The State University of New Jersey)
Rutgers University. Graduate School - New Brunswick
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Type
License
Name
Author Agreement License
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I hereby grant to the Rutgers University Libraries and to my school the non-exclusive right to archive, reproduce and distribute my thesis or dissertation, in whole or in part, and/or my abstract, in whole or in part, in and from an electronic format, subject to the release date subsequently stipulated in this submittal form and approved by my school. I represent and stipulate that the thesis or dissertation and its abstract are my original work, that they do not infringe or violate any rights of others, and that I make these grants as the sole owner of the rights to my thesis or dissertation and its abstract. I represent that I have obtained written permissions, when necessary, from the owner(s) of each third party copyrighted matter to be included in my thesis or dissertation and will supply copies of such upon request by my school. I acknowledge that RU ETD and my school will not distribute my thesis or dissertation or its abstract if, in their reasonable judgment, they believe all such rights have not been secured. I acknowledge that I retain ownership rights to the copyright of my work. I also retain the right to use all or part of this thesis or dissertation in future works, such as articles or books.