FEM Modeling of Effect of Cutting Speeds and Tool-Chip Frictional Coefficients in Orthogonal Machining of Titanium Alloy (Ti-6Al-4V)

Titanium alloys are classified as hard-to-cut materials due to high chemical reactivity and low thermal conductivity. In this paper, the Finite Element Method (FEM) is used to model and simulate effects of cutting speeds and too-chip frictional coefficients in orthogonal machining of Titanium alloy (Ti-6Al-4V). Johnson-Cook plastic model is used to model the workpiece due to its capability of modeling large strains, high strain rates, and temperature dependent visco-plasticity. The tool material is Carbide. Three different cutting speeds (70m/min, 150m/min, and 190m/min) and four different frictional coefficients (0.3, 0.5, 0.7, and 1.0) are used to explore the effects of the cutting speeds and frictional coefficients on the cutting temperature, cutting forces, and chip morphology. This model provides fundamental understanding of cutting mechanics of the orthogonal cutting of Titanium alloy (Ti-6Al-4V).