Prediction of Temperature and Stress Distribution During Micro-Cutting of Ti-6Al-4V

A finite element method (FEM) for predicting the temperature and stress distribution in micro-cutting of Ti-6Al-4V is presented. The flow stress of Ti-6Al-4V is taken as a function of strain, strain rate and temperature in order to reflect realistic behavior in machining process. Diamond cutting tool is used. From simulation, cutting force, thrust force, cutting temperature and distribution of cutting temperature and stress are obtained. The effects of cutting speed and uncut chip thickness on the maximum temperature and maximum shear stress are analyzed and size effect is observed. The simulation results show that in micro-cutting of Ti-6Al-4V the maximum temperature locates on the shear plane. And the maximum shear stress locates on the stick region. The maximum temperature decreases as the uncut chip thickness decreases, and it increases with an increase in cutting speed. The maximum shear stress increases as the uncut chip thickness decreases, and it decreases with an increase in cutting speed.