TC4 titanium alloy has excellent comprehensive properties. Due to its light weight, high specific strength, and good corrosion resistance, it is widely used in aerospace, military defense, and other fields. Given that titanium alloy components are often fractured by impact loads during service, studying the fracture behavior and damage mechanism of TC4 titanium alloy is of great significance. In this study, the Johnson–Cook failure model parameters of TC4 titanium alloy were obtained via tensile tests at room temperature. The mechanical behavior of TC4 titanium alloy during the tensile process was determined by simulating the sheet tensile process with the finite element software ABAQUS. The macroscopic and microscopic morphologies of tensile fracture were analyzed to study the deformation mechanism of the TC4 titanium alloy sheet. The results provide a theoretical basis for predicting the fracture behavior of TC4 titanium alloy under tensile stress.

Titanium alloy has been widely used in aerospace, military, and national defense, and other high-tech fields due to its advantages of light weight, high specific strength, excellent corrosion resistance, excellent heat resistance, and good low-temperature performance. In the turning of titanium alloys, a significant quantity of continuous chips with poor breakability is generated. Recycling these titanium chips can effectively reduce raw material costs and minimize environmental impacts, as it decreases the dependency on primary titanium sources. The titanium chip crushing process is an indispensable part of the titanium chip recovery process, and the double-teeth roll crushing process is the most commonly used metal crushing process. Finite element simulation is an efficient, time-saving, and resource-saving method to optimize the titanium chip crushing process. In this paper, the stress change in the process of titanium chip crushing is analyzed by finite element simulation, and the influence of the number of cutter roller teeth and the speed of the cutter roller on the crushing effect of the titanium chip is analyzed. The optimal process parameters of the titanium chip crusher were obtained by response surface optimization, and the accuracy of the finite element simulation was verified by experiments, which provided a theoretical and practical basis for optimizing the titanium chip crushing process.