Predicting cutting force and simulating material removal process in turning TiCp/Ti6Al4V composite

Particle-reinforced titanium matrix composites (PTMCs) are high-performance composites. However, the current simulation of particle reinforced composites is based on a simplified morphology of reinforced particles, which is inconsistent with the actual particle geometry. This paper presents an improved PTMC simulation model based on image recognition; a finite element model considering particle geometry and material damage behavior is established. Simultaneously, related turning tests are carried out to verify the accuracy of the model built in this research in terms of predicting cutting forces and simulating material removal processes based on cutting forces, chip microstructure, and particle failure forms. The results indicate that the cutting speed is directly proportional to the cutting force along the same path, and the cutting force change trend is essentially the same. Cutting depth has a substantial impact on the cutting force and its trend. The substrate mainly slides along the shear surface to form chips, and the chips on the free surface bend and break in the forming process, and the final chip morphology is serrated. During the cutting process, the matrix plastic deformation and the tool extrusion influence the direction of particle fracture, and particles with a fracture angle of 45° are more likely to form gaps on the machined surface.