Finite Element Modelling of Cutting Forces in Turning of Ti–6Al–4V Alloy

Abstract

Titanium alloys are commonly used in aviation industries, and the reasons for using titanium alloys when compared to commonly available materials are high strength-to-weight ratio, mechanical properties and corrosion resistance. All these superior properties result in a major disadvantage, that is poor machinability. Excessive cutting forces and heat are generated during machining of titanium alloys so that induces poor tool life. Experimental studies of conventional machining on these materials are expensive and time-consuming. So, a dynamic 3D finite element model was developed in ABAQUS for predicting the cutting force in turning process considering the Lagrangian formulation for meshing and considering the tool as flexible. With the help of FE model, the process parameters such as cutting speed, feed and depth of cut can be optimized for cutting forces, which results in power savings as well as increased productivity in turning process of difficult to machine materials.