Comparative Study on Cutting Force Simulation Using DEFORM 3D Software during High Speed Machining of Ti-6Al-4V

Abstract

The finite element-based machining simulations for evaluation/computation of different machining responses (i.e., cutting temperature, tool wear, cutting force, and power/energy consumption) are investigated by number of researchers. In this work, finite element machining simulation was performed to obtain knowledge about cutting forces during machining of hard materials. Titanium alloy (Ti-6Al-4V) has been increasingly used in aerospace and biomedical applications due to high toughness and good corrosion resistance. The high speed machining (HSM) simulation of Ti-6Al-4V work-piece using carbide tool coated with TiCN has been conducted with different combination of cutting conditions for prediction of main cutting force (Fz). The simulated result obtained from Deform 3D software is validated with experimental result and it was found that the result found in good agreement. The parametric variation shows that depth of cut and feed are influencing parameters on cutting force.

Computer-aided design system for the end mill made by laser ablation and grinding

“…High-speed milling is characterized not only by a high material removal rate, but also by a low cutting force [7][8][9][10], small deformation [11], easy penetration of the mechanism due to the kinematic sharpening of the cutting wedge [12,13], high quality processing and is widely used in production ensuring the high perfamance of production [14][15][16]. In fast machining with cutting speed detection, the chips are deformed too late and flow out of the rake face.…”