Investigation on machining of a Ti–6Al–4V alloy using FEM simulation and experimental analysis
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Date
2022-12-07
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Abstract
Titanium alloys have been attracting from the more industries, especially, industry aerospace due to their very important high
strength to weight ratio. Furthermore, they were classified as difficult to machine materials due to low tool life in machining
processes. In this study, a FE model has been developed to simulate the turning stage of Ti–6Al–4V alloy. A 3D model
with thermo-mechanical coupling has been proposed to study the influence of cutting parameters and also lubrication on
the performance of cutting tools. The constants of the Johnson–Cook constitutive model of Ti–6Al–4V alloy were identified
using inverse analysis based on the process parameters of the orthogonal cutting. The predictive FE model has been validated
based on an orthogonal cutting test. The investigations indicated that this approach estimates the resultant cutting forces with
low prediction errors. Indeed, the predicted forces showed good agreement with the experimental data, with minimum and
maximum error magnitudes of 2.8 and 8.7% for cutting force, and 1.3 and 6.8% for feed force, respectively.