Exploring the influence of constitutive models and associated parameters for the orthogonal machining of Ti6Al4V

Ti6Al4V is known as difficult-to-cut material due to its inherent properties such as high hot hardness, low thermal conductivity and high chemical reactivity. Though, Ti6Al4V is utilized by industrial sectors such as aeronautics, energy generation, petrochemical and bio-medical etc. For the metal cutting community, competent and cost-effective machining of Ti6Al4V is a challenging task. To optimize cost and machining performance for the machining of Ti6Al4V, finite element based cutting simulation can be a very useful tool. The aim of this paper is to develop a finite element machining model for the simulation of Ti6Al4V machining process. The study incorporates material constitutive models namely Power Law (PL) and Johnson – Cook (JC) material models to mimic the mechanical behaviour of Ti6Al4V. The study investigates cutting temperatures, cutting forces, stresses, and plastic strains with respect to different PL and JC material models with associated parameters. In addition, the numerical study also integrates different cutting tool rake angles in the machining simulations. The simulated results will be beneficial to draw conclusions for improving the overall machining performance of Ti6Al4V. (paper)