Effect of dynamic properties of materials on serrated chip formation during Ti6Al4V alloy drilling process

Effect of dynamic properties of materials on serrated chip formation during Ti6Al4V alloy drilling process | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Effect of dynamic properties of materials on serrated chip formation during Ti6Al4V alloy drilling process Zhaoju Zhu, Guang Ouyang, Shiying Geng This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7511973/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 22 Nov, 2025 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 5 You are reading this latest preprint version Abstract Titanium alloy is widely used in aerospace field because of its high specific strength, low modulus of elasticity and corrosion resistance. However, in its drilling process, the generation of serrated chips is easy to induce the fluctuation of cutting force, which has a serious impact on the machining quality and tool wear, and the dynamic properties of the material are the main factors affecting the formation of serrated chips. In order to study the influence of the dynamic properties of titanium alloys on the formation of serrated chips in drilling, the forming mechanism of serrated chips in drilling Ti6Al4V alloy is investigated by using a combination of theoretical analysis and finite element simulation; the mechanism of cyclic change of strain and cutting force in the process of serrated element formation is elucidated. Using the parameters of chip serrated degree sensitivity and serrated frequency sensitivity as evaluation indexes, the influence laws of different Johnson-Cook (J-C) constitutive model parameters and J-C damage model parameters on the chip morphology were revealed, and the J-C constitutive model parameters were optimized for the workpiece materials. The results further reveal the forming mechanism of serrated chips in the drilling process of titanium alloy and provide guidance for the optimization of process parameters and surface quality control. Finite element simulation Ti6Al4V alloy Serrated chips Johnson-Cook constitutive model Full Text Cite Share Download PDF Status: Published Journal Publication published 22 Nov, 2025 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Minor Revisions Needed 27 Oct, 2025 Reviewers agreed at journal 04 Sep, 2025 Reviewers invited by journal 04 Sep, 2025 Editor assigned by journal 02 Sep, 2025 First submitted to journal 01 Sep, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7511973","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":510219591,"identity":"e4fe982f-daa3-4375-803c-d5b772c58aba","order_by":0,"name":"Zhaoju Zhu","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAA9ElEQVRIie3PMWuDUBDA8ZMDpfBM1yuF+BWUt2QI/SyK4CSlJUuGUB4ITiWzoaFfIpD5hYNk8QNkTfsFBKFjqQ4lm76x0PeHgxvuNxyAzfYXIwCEfhC1bpY0DcyJVyaHqp7JSBkSAFFLvimXCegREby9yvZpNffCcxyy806xo/DycR4gzrYOZXXMsCMxP+/p0QNXynyAIOVhKlzuiebNnhaOEu79EHE7wuK7J4lif0uJ0iNEUB4VftmRmoF9ZUCIsgX66wzvTiUcqiPJqBj5JajSXSu+5umEb9umWb1MA6+4fA6R39LrigbnfQ+GdzabzfYf+wE4hEtuxsVCsAAAAABJRU5ErkJggg==","orcid":"","institution":"Fuzhou University","correspondingAuthor":true,"prefix":"","firstName":"Zhaoju","middleName":"","lastName":"Zhu","suffix":""},{"id":510219592,"identity":"36fb5f74-e5a2-4b8e-b40a-c2e5a9d87e07","order_by":1,"name":"Guang Ouyang","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Guang","middleName":"","lastName":"Ouyang","suffix":""},{"id":510219593,"identity":"e590f90f-aa0d-4175-9b43-69f078813718","order_by":2,"name":"Shiying Geng","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Shiying","middleName":"","lastName":"Geng","suffix":""}],"badges":[],"createdAt":"2025-09-02 00:33:23","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-7511973/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-7511973/v1","draftVersion":[],"editorialEvents":[{"content":"https://doi.org/10.1007/s00170-025-16963-0","type":"published","date":"2025-11-22T15:57:09+00:00"}],"editorialNote":"","failedWorkflow":false,"files":[{"id":96650019,"identity":"af037b6e-2740-47da-a22e-ed6a80bcdebe","added_by":"auto","created_at":"2025-11-24 16:04:57","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":1898044,"visible":true,"origin":"","legend":"","description":"","filename":"manuscript.pdf","url":"https://assets-eu.researchsquare.com/files/rs-7511973/v1_covered_4eb9642e-29bf-4824-b3a8-b39ff4fc31a3.pdf"}],"financialInterests":"","formattedTitle":"Effect of dynamic properties of materials on serrated chip formation during Ti6Al4V alloy drilling process","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Finite element simulation, Ti6Al4V alloy, Serrated chips, Johnson-Cook constitutive model","lastPublishedDoi":"10.21203/rs.3.rs-7511973/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7511973/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eTitanium alloy is widely used in aerospace field because of its high specific strength, low modulus of elasticity and corrosion resistance. However, in its drilling process, the generation of serrated chips is easy to induce the fluctuation of cutting force, which has a serious impact on the machining quality and tool wear, and the dynamic properties of the material are the main factors affecting the formation of serrated chips. In order to study the influence of the dynamic properties of titanium alloys on the formation of serrated chips in drilling, the forming mechanism of serrated chips in drilling Ti6Al4V alloy is investigated by using a combination of theoretical analysis and finite element simulation; the mechanism of cyclic change of strain and cutting force in the process of serrated element formation is elucidated. Using the parameters of chip serrated degree sensitivity and serrated frequency sensitivity as evaluation indexes, the influence laws of different Johnson-Cook (J-C) constitutive model parameters and J-C damage model parameters on the chip morphology were revealed, and the J-C constitutive model parameters were optimized for the workpiece materials. 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