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<p>This study investigates the cutting behavior of laminated titanium alloy/carbon fiber composites under lubrication-assisted conditions, aiming to elucidate the mechanisms by which key parameters—such as cutting speed, tool rake angle, and cutting depth—affect machining responses including residual stress, cutting force, and tool temperature. A multiphysics coupled finite element simulation model was established using the Abaqus/Explicit module to simulate three machining scenarios: conventional cutting of Ti metal, Ti/C composites, and lubrication-assisted cutting. Cohesive elements were introduced to approximate the actual interfacial properties of the composite, and an Euler–Lagrangian mixed mesh technique was employed to simulate the lubricant flow field. The results show that cutting depth is the primary factor influencing residual compressive stress. In Ti/C cutting, due to fiber fracture, delamination, and anisotropy, residual stress is significantly higher than in single Ti cutting. A tool rake angle of 15° yields the lowest residual stress, while an increase in cutting speed results in a rise in thermally induced residual stress. Lubrication-assisted cutting effectively reduces peak residual stress by more than 15% through lowering friction and thermal input. Cutting force analysis indicates that both X- and Y-directional forces increase with cutting depth and speed, with the X-direction force being more sensitive. Compared with conventional Ti cutting, fiber-reinforced composites exhibit overall lower cutting forces due to their structural buffering mechanisms, while lubrication further suppresses peak forces and enhances stability. Increasing the tool rake angle reduces contact area and shear load, thereby significantly decreasing cutting forces, with lubrication conditions offering more pronounced control. Regarding tool temperature, both higher cutting speed and depth intensify thermal accumulation: under dry cutting, tool temperature can reach up to 110 °C, whereas lubrication leads to a milder temperature rise, with a maximum of only about 40 °C. The effect of tool rake angle on temperature shows a rise-then-fall trend, peaking at 15°, attributed to concentrated heat generation from shear and friction at this angle. Lubrication-assisted cutting effectively weakens heat sources and promotes thermal diffusion, significantly improving the thermal conductivity performance of the tool.</p>

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Study on the Cutting Mechanism of Titanium Alloy/Carbon Fiber Composite under Lubrication Assistance

  • 期刊论文

  • 发表日期：

    2026年1月10日

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  • Ping Zhang,
  • Shuai Ge,
  • Yan Yu,
  • Tengfei Zhang

摘要

This study investigates the cutting behavior of laminated titanium alloy/carbon fiber composites under lubrication-assisted conditions, aiming to elucidate the mechanisms by which key parameters—such as cutting speed, tool rake angle, and cutting depth—affect machining responses including residual stress, cutting force, and tool temperature. A multiphysics coupled finite element simulation model was established using the Abaqus/Explicit module to simulate three machining scenarios: conventional cutting of Ti metal, Ti/C composites, and lubrication-assisted cutting. Cohesive elements were introduced to approximate the actual interfacial properties of the composite, and an Euler–Lagrangian mixed mesh technique was employed to simulate the lubricant flow field. The results show that cutting depth is the primary factor influencing residual compressive stress. In Ti/C cutting, due to fiber fracture, delamination, and anisotropy, residual stress is significantly higher than in single Ti cutting. A tool rake angle of 15° yields the lowest residual stress, while an increase in cutting speed results in a rise in thermally induced residual stress. Lubrication-assisted cutting effectively reduces peak residual stress by more than 15% through lowering friction and thermal input. Cutting force analysis indicates that both X- and Y-directional forces increase with cutting depth and speed, with the X-direction force being more sensitive. Compared with conventional Ti cutting, fiber-reinforced composites exhibit overall lower cutting forces due to their structural buffering mechanisms, while lubrication further suppresses peak forces and enhances stability. Increasing the tool rake angle reduces contact area and shear load, thereby significantly decreasing cutting forces, with lubrication conditions offering more pronounced control. Regarding tool temperature, both higher cutting speed and depth intensify thermal accumulation: under dry cutting, tool temperature can reach up to 110 °C, whereas lubrication leads to a milder temperature rise, with a maximum of only about 40 °C. The effect of tool rake angle on temperature shows a rise-then-fall trend, peaking at 15°, attributed to concentrated heat generation from shear and friction at this angle. Lubrication-assisted cutting effectively weakens heat sources and promotes thermal diffusion, significantly improving the thermal conductivity performance of the tool.