Impact of cutting parameters on machining of Ti-6Al-4V alloy: an experimental and FEM approach

Titanium alloys are used as an aerospace material due to their inherent properties such as high strength to weight ratio, corrosion, and fracture resistance. However, the low conductivity and reactivity towards plastic deformation causes these materials to be difficult to cut category. The prediction of various parameters like chip formation and actual cutting forces are important factors for better machinability which involves lot of resources. To overcome such issues, this work proposes three-dimensional FE approach to simulate the machinability behavior of Ti-6Al-4V especially on conventional turning. The impact of cutting speed and feed rate on the cutting force, thrust force, feed force and surface roughness were analyzed experimentally for various conditions. The predicted machining forces showed strong correlation with the experimental results and the effective von mises stress were examined.