Finite element modelling to predict cutting parameters for milling on titanium alloy (Ti-6Al-4V)

Abstract

Finite element modelling (FEM) is considered a very important tool for estimating the cutting forces and stress-strain analysis because it can produce very accurate results, minimise the costs of manufacturing, and machining time saving as well. The present work predicts the cutting parameters by FEM after conducting the experimental process of titanium alloy (Ti-6Al-4V) by using a face milling operation. In addition, finite element modelling has been proven in simulation of titanium alloy (Ti-6Al-4V) dry cutting. The experimental tests were performed at several axial depths of cut while the feed rate and cutting speed remained constant. The test results led to the conclusion that the axial depth of cut directly affects cutting parameters during the machining process of titanium alloy (Ti-6Al-4V) and thus surface finish during production. The effects on cutting force components are more obvious than on stress and strain components. Besides that, it was found that the axial depth of cut affects the main cutting force more than the feed cutting force. © Institution of Engineers Australia, 2013.