Finite element modelling to predict cutting parameters for milling on titanium alloy (Ti-6Al-4V)

Abstract

Finite element modelling (FEM) is considered a very important tool for estimating the cutting forces and stress-strain analysis because it can produce very accurate results, minimise the costs of manufacturing, and machining time saving as well. The present work predicts the cutting parameters by FEM after conducting the experimental process of titanium alloy (Ti-6Al-4V) by using a face milling operation. In addition, finite element modelling has been proven in simulation of titanium alloy (Ti-6Al-4V) dry cutting. The experimental tests were performed at several axial depths of cut while the feed rate and cutting speed remained constant. The test results led to the conclusion that the axial depth of cut directly affects cutting parameters during the machining process of titanium alloy (Ti-6Al-4V) and thus surface finish during production. The effects on cutting force components are more obvious than on stress and strain components. Besides that, it was found that the axial depth of cut affects the main cutting force more than the feed cutting force.

Keywords:

• Finite element modelling (FEM)
• axial depth of cut
• milling cutting process
• titanium alloy (Ti-6Al-4V)

Additional information

Notes on contributors

M H Ali

Moaz Ali graduated from the Al-Rashid School and he received a BSc in Mechanical Engineering from the Babylon University, Iraq. He completed and received a Masters degree in manufacturing processes from the University Donetsk National Technical, Donetsk, Ukraine. Now he is a PHD student at Universiti Tenaga Nasional, Putra Jaya, Malaysia. His research interests include finite element modelling to predict the machining parameters of titanium alloy.

B A Khidhir

Basim Khidhir has a PhD in manufacturing engineering, and MSc and BSc degrees in production engineering (metal cutting). He is an associate professor at Sulaimanyah Technical College, Iraq.

M N M Ansari

M Ansari has a PhD in polymer engineering from Universiti Sains Malaysia, MEng in computer integrated manufacturing from Anna University, India, PG Diploma in plastics engineering from CIPET, India, and BEng in mechanical engineering from University of Madras, India. He is a lecturer with the Department of Mechanical Engineering, Universiti Tenaga Nasional, Putra Jaya, Malaysia.

B Mohamed

Bashir Mohamad has PhD and BSc degrees in mechanical engineering. He is an associate professor at Universiti Tenaga Nasional, Malaysia.