Experimental Investigation of Process Parameters in Orthogonal Machining of Ti6Al4V with TiC Coated PCBN Inserts – A Finite Element Analysis

Abstract

Aeronautical industry requires material having high resistance as well as high hardness. As it is common fact that, the machining of these metals has continuously been a boundless task. Metal cutting of these titanium alloys required for cutting great-strength materials, which occasionally is not cost-effective and from time to time even unreasonable. These metals incline to stick to the machining tool surface and chips are stuck to the flank. This sticking of cut materials will induce tool damage entailing a reduction of tool life. It also affects the surface roughness and perfection in dimension of finished product. To evade the prerequisite of wide-ranging experiments and to appreciate the orthogonal material removal of Ti6Al4V, FEA is employed. This work mainly focuses on learning the impact of metal cutting parameters on machinability of Ti6Al4V using PCBN tool inserts in dry machining and by analyzing the stress, temperature and effective strain scattering through finite element analysis. Various experiments were conducted by varying the machining speeds and feed rates. The machining process was also simulated in DEFORM – 2D software to study the corresponding effective strain, effective stress, and the temperature scattering.