On different FE-based models to simulate cutting operation of Titanium alloy (Ti-6Al-4V)

Abstract

Finite element based models for cutting operation present outstanding complexities due to their nonlinear and multi-physics coupling. Nevertheless, there is no uniform standard for the comparison between cutting simulation models based on different software. The present work deals with various methodologies to simulate orthogonal cutting operation for Ti-6Al-4V Titanium alloy inside two commercial codes: ABAQUS and DEFORM. The aim is to show how considered optimal FE numerical approaches can imply agreements or disparities in outputs between the two pre-cited codes. In order to carry out a comparative study between the two codes, similar conditions concerning geometrical models and cutting parameters were adopted. A multi-physic comprehension related to chip formation, cutting forces, temperature evolutions, and surface integrity was presented. Moreover, the numerical results were compared with experimental ones for a deeper discussion on numerical predictions, and problems with current simulation were addressed to improve and support process innovations.