Investigation of cutting responses during high-speed machining of Ti6Al4V alloy: Finite element analysis

Titanium alloy is one of the most widely used materials in cutting-edge technology sectors such as aerospace. In this sector, a significant portion of the components are obtained through the machining process with tight tolerances. It is well known that machining has a considerable effect on surface integrity, which in turn influences the fatigue life of these components. This work deals with numerical investigation into the impact of cutting parameters, namely, cutting speed, depth of cut, and rake angle, on cutting responses such as chip morphology, cutting forces, and residual stress. The cutting model is simulated using the Lagrangian approach through the finite element method. The Johnson-Cook-based model implemented in ABAQUS/Explicit is used to simulate the high-speed dry-cutting process of Titanium Ti-6Al-4V alloy as a 2D orthogonal cutting. This model is validated against experimental data reported in published literature. The main findings are presented and discussed.