Towards inverse simulation: Effect of material parameters on machining predictions

Abstract

Machining is a quite relevant process on industry. However, despite its industrial importance, many parameters of the process are still chosen through empirical testing which is traduced in high time-consuming and costs. Based on that, an alternative approach to empirical methods is needed. Any other approach (numerical, analytical) needs a previous material characterization, which clearly influences on the accuracy of the predictions. This paper studies the effect that material characterization has on fundamental variables predictions, such as cutting forces, temperature and strain rate. A comprehensive analytical study has been carried out, based on Oxley theory and Johnson-Cook material law. Also the contact was considered, qualitatively, based on Coulomb friction law. The final aim of the paper is to present a comprehensive sensitivity study of the flow stress parameters for a widely used aeronautical alloy (Ti-6Al-4V).