Machining Model of Ti-6Al-4V Titanium Alloy Using Fem Simulation

MACHINING MODEL OF Ti-6Al-4V TITANIUM ALLOY USING

FEM SIMULATION
Hadzley, M.M.A., Raja Izamshah, R.A., Amran, M.M.A.
Department of Manufacturing Process,
Faculty of Manufacturing Engineering,
UniversitiTeknikal Malaysia Melaka,
Hang Tuah Jaya, 76100
Durian Tunggal, Melaka, Malaysia
Email: hadzley@utem.edu.my
ABSTRACT: This paperpresents a machining modelof Ti-6Al4V titanium alloy using finite element method (FEM) simulation.
The constitutive JohnsonCook material flow stress was employed
to predict material plasticity, chip morphology, cutting forces and
stress distribution. Comparative analysis for both simulation and
experimental data were carried out. The simulated results show
that workpiece material flow around the cutting edge of the tool
and deposited themselves to form a continuous curl chip formation.
The stress distribution generated in the shearing plane during
steady state conditions and the residual stress is formed beneath
the machined surface.The cuttingforces were essentially constant
across the range of cutting speeds. This agreedwith the trend from
the experimental trials.
KEYWORDS: Machining, Ti-6Al-4V alloy, FEM.

1.0 INTRODUCTION
Since their introduction in the early 1950s, Ti-6Al-4V alloys have become
the backbone materials of choice for aerospace, marine, medical and
other major industrial applications. The combination of high strengthto-weight ratio, excellent mechanical properties and corrosion resistance
have led to titanium alloys being used in a wide and diversified range
of successful applications (Ezugwu, E. O., Bonney, J. and Da Silva, R.
B., 2007) However, this material is known to be difficult to machine due
to its low thermal conductivity which gives rise to high temperatures
at the toolchip and tool-workpieceinterfaces. Therefore, the cutting
process of Ti-6Al-4V is associatedwith complex physical phenomenon
which is difficult to comprehend by direct experimental alone.

ISSN: 1985-3157

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No. 2

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Journal of Advanced Manufacturing Technology

Over the past two decades, finite element method (FEM)has been used
extensively in the investigation of machining processes.Some of the
commercial softwaresthat cansimulate machining process are Nike2D,
Abaqus, Marc, Deform, Forge, Algor, Fluent, AdvantedgeandLsDyna(Soo, S.L. and Aspinwall, D.K., 2007). Early simulations of
machining processes were carried out by Usui and Shirakashi (Usui, E.
and Shirakashi, T., 1982) by analyzing steady-state orthogonal cutting.
Carroll and Strenkowski (Carroll, J.T. and Strenkowski, C., 1998),
attempted chip formation and separation from the workpiece. Hua and
Shivpuri (Hua, J. and Shivpuri, R., 2004), simulated chip formation
of machining based on deformation energy-based criterion (Umbrello,
D., 2008)focussedon damage criterion and friction to simulate chip
morphology during machining. To deal with large element distortion,
(Rui, L. and Shih, A. J., 2006),developed 3D model to simulate chip
formation during machining.(Calamaz et.al 2008), Calamazmodified
the Johnson-Cook constitutive model to simulate serrated chip
formation. Many studies have described the stability and thesimulation
of the machining process for hardened metal and high strength alloy.
However, few works consider the machining simulation of Ti-6Al-4V
alloy.
In this study, FEM machining simulations of Ti-6Al-4V alloy is carried
out using commerciallyavailable software Ls-Dyna 4.21. The purpose of
the study is to understand the underlying mechanism when machining
Ti-6Al-4V alloy. A simulation model of machining process have been
developed based on the Lagrangian formulation with Johnson-Cook
plasticity model. Experimental chip formation, together with cutting
force data were compared with the predicted output from the model.
Correct simulation of the cutting process enables good predictions in
terms of chip formation, strain and stress distribution at the cutting
interfaces. This will contribute to significant cost reduction for
machining process optimisation which at the moment is still carried
out experimentally.

2.0 METHODOLOGY
2.1

Finite element model

Figure 1 shows the FEM model for the cutting process. Lsprepost 2.1
was used to prepare finite element mesh. The workpiece material was
built from 8012 nodes and 3000 element while the cutting tool was built
from 2134 nodes and 768 elements. Boundary conditions were applied
on the bottom and right side nodes of the workpiece and the tool was

ISSN: 1985-3157

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Machining Model of Ti-6Al-4V Titanium Alloy Using Fem Simulation

constrained against vertical displacement and rotation. The total time

of simulated machining process was 2.0mswith cutting speeds varied
from 110 m/min to 130 m/min and feed rateconstant at 0.15 mm/rev.
For simplicity, a cutting tool was modelled as rigid and the coefficient
of friction between cutting tool and workpiece material was assumed
to be 0.3 based on the coulomb friction law.

Figure1
FEMFEM
model
for for
thethe
cutting
Figure1
model
cuttingprocess
process
Figure1
Figure1
FEM
FEM
model
model
forfor
thethe
cutting
cutting
process
process
2.2 Material
Material Properties
2.2
Properties
2.22.2 Material
Material
Properties
Properties
To describe the material response, the constitutive model proposed by
To describe the material response, the constitutive model proposed by Johnson-Cook was
Johnson-Cook
was
utilized
in
this
study.model
Johnson-Cook
material
model
To To
describe
describe
thethe
material
material
response,
response,
thethe
constitutive
constitutive
model
proposed
proposed
by by
Johnson-Cook
Johnson-Cook
waswas
utilized
in thisby
study. Johnson-Cook material model is expressed by
isutilized
expressed
utilized
in this
in this
study.
study.
Johnson-Cook
Johnson-Cook
material
material
model
model
is expressed
is expressed
by by

'
T Tom
n
A B n n 1 C ln' ' 1 T TTo To
A AB B 1 1C lnC ln ' o1 1 Tmelt To
TmeltTo To
' o ' o Tmelt

m
m

....(3.1)
....(3.1)
....(3.1)

where is the flow stress, is the plastic strain, is the strain rate, o is the reference plastic
where
where
isthe
is the
flow
flow
stress,
stress,
isthe
is the
plastic
plastic
strain,
strain,
isthe
is the
strain
strain
rate,
rate,
o
isothe
is the
reference
reference
plastic
plastic
strain, T is the workpiece temperature, Tmeltis the melting temperature of the workpiece
where
flow
stress,
is the
strain,

is
the
strain
rate,
o
strain,
strain,
TisTisthe
isthe
the
workpiece
workpiece
temperature,
temperature,
TmeltTplastic
is
the
is
the
melting
melting
temperature
temperature
of
of
the
the
workpiece
workpiece
melt
material
and To is the
room temperature.
Thethe
constant
coefficienttemperature,
A is the yield strength,
B is
ismaterial
the
reference
plastic
strain,
T
is
workpiece
T
material
andand
To is
Tothe
is the
room
room
temperature.
temperature.
TheThe
constant
constant
coefficient
coefficient
A isAthe
is the
yield
yield
strength,
strength,
B isBisis
melt
the
hardening
modulus,
C
is
the
strain
rate
sensitivity
coefficient,
n
is
the
hardening
the
melting
temperature
of strain
thestrain
workpiece
material
and
Tn o is
is the
room
thethe
hardening
hardening
modulus,
modulus,
C C
is is
thethe
raterate
sensitivity
sensitivity
coefficient,
coefficient,
n is
thethe
hardening
hardening
temperature.
constant
coefficient
A is All
theparameters
yield strength,
is the
coefficient andThe
m is the
thermal softening
coefficient.
used in this B
study
were
coefficient
coefficient
andand
m ism the
is the
thermal
thermal
softening
softening
coefficient.
coefficient.
AllAll
parameters
parameters
used
used
in this
in this
study
study
were
were
hardening
modulus,
C
is
the
strain
rate
sensitivity
coefficient,
n
is
the
determined by Lee and Lin (Lee, W.S. and Lin, C.F., 1998), as shown in Table 1.
determined
determined
by coefficient
by
LeeLee
andand
LinLin
(Lee,
(Lee,
W.S.
W.S.
Lin,
Lin,
C.F.,
C.F.,
1998),
1998),
as
shown
as shown
in Table
incoefficient.
Table
1. 1.
hardening
and
mand
isand
the
thermal
softening
All

parameters used in this study were determined by Lee and Lin (Lee,
Table 1 Overview of the material properties used in the simulations
W.S. and Lin,
C.F.,
1998),of as
shown
inproperties
Tableused
1.used
Table
Table
1 Overview
1 Overview
the
of the
material
material
properties
in the
in the
simulations
simulations
A(MPa) B(MPa)
C
n
A(MPa)
A(MPa) B(MPa)
B(MPa) C C
n n m
782.7
498.4
0.028
0.28
782.7
782.7 498.4
498.4 0.028
0.028 0.28
0.28 1

Failure
m
o(s-1-1)
To (K)
Tmelt(K) Failure
Failure
strain
m o(s-1o(s
) ) To (K)
To (K) Tmelt
Tmelt
(K)(K)
strain
strain
-1
1
1e-5
300
1800
0.3
-1 s -1
1 1e-5
1e-5
s s
300300
1800
1800
0.30.3

2.3
Experimental Setup and Verification
2.32.3 Experimental
Experimental
Setup
Setup
andand
Verification
Verification
The results of FEM models were verified with the machining trials of commercially available
TheThe
results
results
of FEM
of FEM
models
models
were
were
verified
verified
with
with
thethe
machining
machining
trials
trials
of commercially
of commercially
available
available
Ti-6Al-4V alloy. Setup for the machining tests is shown in Figure 2(a). The component forces
Ti-6Al-4V
Ti-6Al-4V
alloy.
alloy.
Setup
Setup
for for
thethe
machining
machining
tests
tests
is shown
is shown
in Figure
in Figure
2(a).
2(a).
TheThe
component
component
forces
forces
were measured using a dynamometer with oscilloscope as shown in Figure2(b). The
were
were
measured
measured
using
using
a dynamometer
a dynamometer
with
with
oscilloscope
oscilloscope
as as
shown
shown
in in
Figure2(b).
Figure2(b).
TheThe
following cutting conditions were employed in this investigation:
following
following
cutting
cutting
conditions
conditions
were
were
employed
employed
in this
investigation:
ISSN:
1985-3157
Vol. 6 in this
No.
2 investigation:
July-December 2012
3
Cutting Speed (m/min):
110, 120 and 130
Cutting
Cutting
Speed
Speed
(m/min):
(m/min):
110,
110,
120120
andand
130130

coefficient and m is the thermal softening coefficient. All parameters used in this study were

Journal
of Advanced
Technology
determined
by LeeManufacturing
and Lin (Lee, W.S.
and Lin, C.F., 1998), as shown in Table 1.
Table 1 Overview of the material properties used in the simulations
Table 1 Overview
of the material properties used in the simulations
A(MPa)
782.7
2.3

B(MPa)
498.4

0.028

0.28

o(s-1)
1e-5 s

To (K)

Tmelt(K)

300

1800

-1

Failure
strain
0.3

Experimental Setup and Verification

2.3

Experimental Setup and Verification

Theresults
results of of
FEM
models
were verified
withverified
the machining
trials
of commercially
The
FEM
models
were
with
the
machiningavailable
trials of
Ti-6Al-4V
alloy.
Setup
for
the
machining
tests
is
shown
in
Figure
2(a).
The
component
forces
commercially available Ti-6Al-4V alloy. Setup for the machining
tests
is were
shown
in Figure
The component
forces
measured
using a2(a).
dynamometer
with oscilloscope
as were
shown measured
in Figure2(b).using
The a
dynamometer
with oscilloscope
shown
in Figure2(b). The following
following cutting conditions
were employedas
in this
investigation:
cutting
conditions
were
employed
in
this
investigation:
Cutting Speed (m/min):
110, 120 and 130
Feed rate (mm/rev):

Cutting Speed (m/min):

Feed rate (mm/rev):

0.15

110, 120 and 130

0.15
(b)

(a)

Figure
2 Experimental
setup
machining
verification.
(a)setup
Machining
Figure
2 Experimental setup
forfor
machining
verification.
(a) Machining
(b)
setup Dynamometer
(b) Dynamometer
withfor
oscilloscope
forforces.
recording
complete complete
with oscilloscope
recording cutting
cutting forces.
3.0

RESULTS AND DISCUSSIONS

3.0

RESULTS AND DISCUSSIONS

3.1

Simulation Results

3.1

Simulation Results

The result of the initial chip formation when modelling of machining Ti-6Al-4V is shown in

The
result of the initial chip formation when modelling of machining
Figure 3.It is clearly shown thatheavy plastic deformation was visible around the region
Ti-6Al-4V is shown in Figure 3.It is clearly shown thatheavy plastic
where the cutting tool penetrated into the workpiece. This region is characterized by the
deformation was visible around the region where the cutting tool
relatively large mesh distortion wheremeshesthat sufficiently strained around 0.3 were
penetrated into the workpiece. This region is characterized by the
automatically deleted to facilitate chip separation. It can be seen from Figure3 that the
relatively
large mesh distortion wheremeshesthat sufficiently strained
deformation
the chip
distorted heavily
at the initial
contact point
3a),then It
around
0.3 of
were
automatically
deleted
to facilitate
chip(Figure
separation.
increasing
sharply
alongFigure3
tool rake face
(Figure
and dropping quickly
to form
a continuous
can
be seen
from
that
the3b)deformation
of the
chip
distorted
chipcurl
(Figure
3c).
heavily at the initial contact point (Figure 3a),then increasing sharply
along tool rake face (Figure 3b) and dropping quickly to form a
continuous chipcurl (Figure 3c).
(a)

(b)

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(c)

Vol. 6

No. 2

July-December 2012

deformation of the chip distorted heavily at the initial contact point (Figure 3a),then
increasing sharply along tool rake face (Figure 3b) and dropping quickly to form a continuous

Machining Model of Ti-6Al-4V Titanium Alloy Using Fem Simulation

chipcurl (Figure 3c).

(b)

(a)

(c)

Figure 3 Chip formation during machining with 110 m/min cutting

speed
at times
of:(a) 0.0005
s (b)
0.001s
(c) speed
0.002atstimes of:(a)
Figure 3 Chip
formation
during machining
with 110
m/min
cutting
0.0005 s (b) 0.001s (c) 0.002 s

Figure 4 shows the comparison between experimental and FEM

resultsfor the chip curl when machining T-6Al-4Valloy at110 m/min
speed.Qualitatively, the morphology of thechip curl obtained from
Figure44shows
showsthe
thecomparison
comparisonbetween
between experimentaland
and FEMresultsfor
resultsforthe
thechip
chipcurl
curlwhen
when
Figure
experiment
(Figure
4(a)) and experimental
FEMmodel FEM
(Figure 4(b))
is generally
machiningT-6Al-4Valloy
T-6Al-4Valloyat110
m/minspeed.Qualitatively,
speed.Qualitatively,the
morphologyofofthechip
curl
machining
m/min
morphology
curl
similar.
The
chip flowat110
directionis
also similarthefor
both thethechip
simulated
obtained
from
experiment
(Figure
4(a))
and
FEMmodel
(Figure
4(b))
is
generally
similar.
The to
obtained from experiment (Figure 4(a)) and FEMmodel
(Figure
4(b)) is generally
similar. The
andexperimentaldata.However,
the finite
element
methodtends
chipflow
flowdirectionis
directionis
also
similarfor
for
both
the
simulatedandexperimentaldata.However,
andexperimentaldata.However,
the33under-predict
thealso
diameter
of
the
experimental
chip curlby about
chip
similar
both
the
simulated
the
finite
elementmethodtends
methodtends
tounder-predict
under-predict
thediameter
diameter
ofthe
theexperimental
experimental
chip
curlby
41%
aselement
shown
in Tableto4.
One
possible
causeofaccording
to Rui
and
Shih
finite
the
chip
curlby
about
33-41%
as
shown
in
Table
4.
One
possible
cause
according
to
Rui
and
Shih
(Rui,
(Rui,
L.
and
Shih,
A.
J.,
2006),
is
the
contact
condition
of
the
chip
with
about 33-41% as shown in Table 4. One possible cause according to Rui and Shih (Rui, L.L.
theand
toolandworkpiece
machining.
Inwith
actual
machining,contact
and
Shih,A.A.J.,J.,2006),
2006),isisthe
theduring
contactcondition
condition
thechip
chip
with
thetoolandworkpiece
toolandworkpiece
during
Shih,
contact
ofofthe
the
during
conditionsuch
as chamfer
and tool
nose radius
significantly
affect
machining.
In
actual
machining,contact
conditionsuch
as
chamfer
and
tool
nose
radiusthe
machining. In actual machining,contact conditionsuch as chamfer and tool nose radius
contact
length
and
width
of
the
chips
in
lateral
and
axial
directionswhile
significantly affect
affect the
the contact
contact length
length and
and width
width ofof the
the chips
chips inin lateral
lateral and
and axial
axial
significantly
in finite
element
modelling,
especially
in
2D,
contact
between
the
tool
directionswhileininfinite
finiteelement
elementmodelling,
modelling,especially
especiallyinin2D,
2D,contact
contactbetween
betweenthe
thetool
tooland
andthe
the
directionswhile
and the workpiece was simplified from the friction, flow stress and
workpiecewas
wassimplified
simplifiedfrom
fromthe
thefriction,
friction,flow
flowstress
stressand
andcutting
cuttingparameters.
parameters.
workpiece
cutting
parameters.
(a)
(a)

(b)
(b)

Comparison
ofchip
chipcurlwhen
curlwhenmachining
machining
speed
110m/min
m/min
Figure Figure
4Figure
Comparison
ofofchip
machining
at aofof
speed
of 110 m/
44Comparison
curlwhen
atata aspeed
110
(a)experimental
experimental(b)
(b)simulation
simulation
min (a)(a)
experimental
(b)
simulation
Table44Comparison
Comparisonofofchips
chipsdiameter
diameterfor
forexperiments
experimentsand
andsimulation
simulation
Table

Table 4 Comparison of chips diameter for experiments and simulation

CuttingSpeeds
Speeds
Cutting
Experiment
Experiment
Simulation
Simulation
Difference
Difference

3.2
3.2

110m/min
m/min
110
2.5-3.5mm
2.5-3.5mm
1.72-2.18mm
mm
1.72-2.18
33-37%%
33-37

120m/min
m/min
120
2.8-3.7mm
mm
2.8-3.7
1.83-2.23
mm
1.83-2.23 mm
35-39%%
35-39

130m/min
m/min
130
2.9-3.9mm
mm
2.9-3.9
1.85-2.28
mm
1.85-2.28 mm
36-41%%
36-41

CuttingForces
Forces
Cutting

Figure55shows
showsthe
the plotsofofrecorded
recordedcutting
cutting forcesfrom
from theexperimental
experimental testsand
and those from
Figure
ISSN:plots
1985-3157
Vol. 6forces
No. 2 the
July-Decembertests
2012 those from
the
simulations.
The
value
of
cutting
forces
is
fluctuated
due
to
the
instability
chip-tool
the simulations. The value of cutting forces is fluctuated due to the instability ofofchip-tool

Journal of Advanced Manufacturing Technology

3.2

Cutting Forces

Figure 5 shows the plots of recorded cutting forces from the

experimental tests and those from the simulations. The value of cutting
forces is fluctuated due to the instability of chip-tool contact resulting
from tool geometry and elasticity of work material as shown in Figure
7. The cutting forces recorded experimentally ranged from 200-208 N
whereas, the simulated cutting forces ranged from 180-184 N as shown
in Figure 6. On average, the simulated data were generally lower than
the experimental data by 11 %. The difference between experimental
and simulation results appear to be reasonable since the FEM modelis
developed with some simplifications and constant assumptions have
developed
with some
some simplifications
simplifications
and constant
constant
assumptions
havematerial
been introducedsuch
introducedsuch
as
developed
with
and
assumptions
have
been
as
been
introducedsuch
as friction
coefficient
and
constitutive
friction coefficient
coefficient and
and material
material
constitutive
model(Yung-Chang, Y.,
Y., et.al.,
et.al., 2004)
2004)
friction
model(Yung-Chang,
model(Yung-Chang,
Y., constitutive
et.al.,
2004)

Figure
Cuttingforce
force distribution
distribution
in 22 ms.
ms.
Figure
5 Cutting
distribution
in 2 ms.
Figure
55 Cutting
force
in

Average
Average Cutting
Cutting Force
Force (N)
(N)

110 m/min
m/min experiment
experiment
110
120 m/min
m/min experiment
experiment
120
130 m/mim
m/mim experiment
experiment
130

3.3
3.3

250
250
200
200

200
200

182
182

110 m/min
m/min simulation
simulation
110
120 m/min
m/min simulation
simulation
120
130 m/min
m/min simulation
simulation
130
208
208

180
180

205
205

184
184

150
150
100
100
50
50
00

Figure
6 Comparison
between
experimental
and simulated
cutting
Figure
Comparison between
between experimental
experimental
and simulated
simulated
cutting forces
forces
Figure
66 Comparison
and
cutting
forces
Stress Distribution
Distribution
Stress

Figure 77 shows
shows the
the distribution
distribution of
of stress
stress in
in the
the work
work material
material after
after 0.005
0.005 ss machining
machining for
for 110
110
Figure

m/min. From
From the
the stress
stress field
field contour
contour plots,
plots, one
one can
can observe
observe that
that plastic
plastic deformation
deformation occurs
occurs in
in
m/min.

ISSN: 1985-3157

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July-December 2012

three regions:
regions: the
the primary
primary deformation
deformation zone
zone which
which stretches
stretches from
from the
the tool
tool tip
tip to
to the
the free
free
three
surface of
of the
the workpiece;
workpiece; the
the secondary
secondary deformation
deformation zone
zone which
which occurs
occurs along
along the
the rake
rake face
face of
of
surface

Machining Model of Ti-6Al-4V Titanium Alloy Using Fem Simulation

3.3

Stress Distribution

Figure 7 shows the distribution of stress in the work material after 0.005
s machining for 110 m/min. From the stress field contour plots, one can
observe that plastic deformation occurs in three regions: the primary
deformation zone which stretches from the tool tip to the free surface of
the workpiece; the secondary deformation zone which occurs along the
rake face of the cutting tool and the tertiary deformation zone which
occurs under the toolchip interface.The primary deformation zone
represent the adiabatic shear plane in cutting zone where large stresses
are imparted to the chip. In particular, it is noted that chip materials just
ahead of the tool tip experience a high level of stress against the tool,
which reflect the abrasive action of the chip upon the tool tip (Lee W. S.
and Lin C. F., 1998). The secondary deformation zone illustrates sliding
ahead of
of the
tip experience
high level
tool, which
reflect the
motion
thetoolchip
on the arake
faceofofstress
theagainst
tool. the
Contact
instabilities
abrasive action
of zone
the chipasupon
the toolof
tipcomplex
(Lee W. S. interaction
and Lin C. F., 1998).
The secondary
appeared
in this
a result
between
friction,
deformation zone
illustrates sliding
of thesoftening
chip on the rake
the tool.material
Contact
temperature
generation
and motion
thermal
of face
theofwork
(Lee,
W. S. and
Lin,in C.
1998).
situation
induces between
fluctuation
instabilities
appeared
thisF.,
zone
as a This
result of
complex interaction
friction,in
cutting
forcegeneration
and represents
the action
of adhesive
in Lin,
theC.tooltemperature
and thermal softening
of the work
material (Lee,wear
W. S. and
F.,
chip1998).
interface
(Lee,
W.
S.
and
Lin,
C.
F.,
1998).
The
tertiary
deformation
This situation induces fluctuation in cutting force and represents the action of adhesive
zone
illustrates
stress in the workpieceoccured just below and behind
wear in the tool-chip interface (Lee, W. S. and Lin, C. F., 1998). The tertiary deformation
the tool tip. The stresses still remain in the surface of the machined
zone illustrates stress in the workpieceoccured just below and behind the tool tip. The stresses
workpiece even when the cutting tool is far away from the shearing
still remain in the surface of the machined workpiece even when the cutting tool is far away
point. This stress is expected to have a strong influence on the formation
from the shearing point. This stress is expected to have a strong influence on the formation of
of residual stresses in the workpiece. Excessive residual stressaffectsthe
residual
stresses in the
workpiece.
Excessive
residual stressaffectsthe
surface integrity
causing
surface
integrity
causing
surface
alteration,
microhardnes
changes
and
surface alteration,
and decreased
fatigue life(Ezugwu,
of the machined
decreased
fatiguemicrohardnes
life of thechanges
machined
components
E. O.,
components
(Ezugwu,
E. O., Bonney,
J. and Da Silva, R. B., 2007).
Bonney,
J. and
Da Silva,
R. B., 2007).

Primary zone
with adiabatic
shear plane

Secondary
zone with
contact
instabilities
Tertiary zone
with residual
stress

Figure7
Stress
from
simulation
after
s forcutting
110 m/min
Figure7
Stresscontours
contours from
thethe
simulation
after 0.005
s for0.005
110 m/min
speed
cutting speed
4.0

CONCLUSIONS

This paper presents a modellingof machining of Ti-6Al-4V titanium alloy FEM simulation.
The JohnsonCooks constitutive equation was implemented and the results were compared

ISSN: 1985-3157
Vol. 6 indicate
No. 2 that
July-December
with experimental
data. Results obtained
a reasonable 2012
prediction of chip 7
morphology and cutting forces for both experimental and simulation. The machining

Journal of Advanced Manufacturing Technology

4.0 CONCLUSIONS
This paper presents a modellingof machining of Ti-6Al-4V titanium
alloy FEM simulation. The JohnsonCooks constitutive equation
was implemented and the results were compared with experimental
data. Results obtained indicate that a reasonable prediction of chip
morphology and cutting forces for both experimental and simulation.
The machining simulation illustrates the distribution of stress in the
primary, secondary and tertiary deformation zones which represent the
interaction of cutting tool and work material during machining. The FE
strategy proposed in this paper generally can be employed to study the
machining process of Ti-6Al-4V alloy and to predict the cutting forces
and the chip formation with reasonable accuracy.

5.0 REFERENCES
Ezugwu, E. O., Bonney, J. and Da Silva, R. B., 2007, Surface Integrity of Finished
Turned Ti6Al4V Alloy with PCD Tools using Conventional and
High Pressure Coolant Supplies, International Journal of Machine
Tools & Manufacture, Vol. 47, 2007, pp. 884891.
Soo, S.L. and Aspinwall, D.K., 2007, Developments in Modelling of Metal
Cutting Processes, Proc. Mech E, part I. Design and Applications.
Orlando, USA, Vol. 221, 2007, pp.197-211.
Usui, E. and Shirakashi, T., 1982, Mechanics of Machining - From Descriptive
to Predictive Theory. On the Art of Cutting Metals - 75 Years Later.
ASME Publication, Vol. 7, 1982, pp.13-35.
Carroll, J.T. and Strenkowski, C., 1998, Finite Element Models Of Orthogonal
Cutting With Application To Single Point Diamond Turning,
International Journal Of Mechanical Science, Vol. 30, No. 12, 1998, pp.
899-920.
Hua, J. and Shivpuri, R., 2004, Prediction of Chip Morphology and
Segmentation During the Machining of Titanium Alloys, Journal of
Materials Processing Technology, Vol. 150, 1-2, 2004, pp. 124-133.
Umbrello, D., 2008, Finite Element Simulation of Conventional and High
Speed Machining of Ti6Al4V Alloy, Journal of Materials Processing
Technology, Volume 196, Vol. 1-3, 2008, pp. 79-87.
Rui, L. and Shih, A. J., 2006, Finite Element Modeling of 3D Turning of
Titanium, International Journal of Advanced Manufacturing
Technology, Vol. 29, 2006, pp. 253261.
Calamaz, M., Dominique, C. and Franck, G. 2008, A New Material Model
for 2D Numerical Simulation of Serrated Chip Formation when
Machining Titanium Alloy Ti6Al4V, International Journal of
Machine Tools and Manufacture, Vol. 48, Issues 3-4, 2008, pp. 275-288.
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No. 2

July-December 2012

Machining Model of Ti-6Al-4V Titanium Alloy Using Fem Simulation

Ls-dyna., 2007, Users Keyword Manual, Volume 1, Version 971, LTSC, May
2007.
Trent, E. M., 1991, Metal Cutting, Fourth Edition, Butterworth-Heinemann
Ltd., 1991.
Yung-Chang, Y., Anurag, J. and Taylan A., 2004, A Finite Element Analysis of
Orthogonal Machining using Different Tool Edge Geometries, Journal
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Lee W. S. and Lin C. F., 1998, Plastic Deformation and Fracture Behaviour
of Ti6Al4V Alloy, Loaded with High Strain Rate under Various
Temperatures, Materials Science and Engineering A, Vol. 241, 1998,
pp. 4859.

ISSN: 1985-3157

Vol. 6

No. 2

July-December 2012