Abstract
The titanium alloys (Ti-6Al-4V) have been widely used in aerospace, and medical applications and the demand is ever-growing due to its outstanding properties. In this paper, the finite element modeling on machinability of Ti-6Al-4V using cubic boron nitride and polycrystalline diamond tool in dry turning environment was investigated. This research was carried out to generate mathematical models at 95% confidence level for cutting force and temperature distribution regarding cutting speed, feed rate and depth of cut. The Box-Behnken design of experiment was used as Response Surface Model to generate combinations of cutting variables for modeling. Then, finite element simulation was performed using AdvantEdge®. The influence of each cutting parameters on the cutting responses was investigated using Analysis of Variance. The analysis shows that depth of cut is the most influential parameter on resultant cutting force whereas feed rate is the most influential parameter on cutting temperature. Also, the effect of the cutting-edge radius was investigated for both tools. This research would help to maximize the tool life and to improve surface finish.
Highlights
Titanium and its alloys are widely used in aerospace and aircraft applications since 1950
Earlier studies have shown that cubic boron nitride (CBN) and Polycrystalline diamond polycrystalline diamond (PCD) tools are typically used for machining of titanium at high cutting speed due to their excellent wear resistance [2, 5]
Literature review shows that the machining of titanium alloy with CBN and PCD tools have been limited in turning process
Summary
Titanium and its alloys are widely used in aerospace and aircraft applications since 1950. 2D finite element modeling was done to study the temperature distribution and cutting forces. Earlier studies have shown that CBN and Polycrystalline diamond PCD tools are typically used for machining of titanium at high cutting speed due to their excellent wear resistance [2, 5]. Earlier studies show that increase in cutting speed increases the temperature at the tool-chip interface due to the low thermal conductivity of the titanium [6]. Calamaz [11] stated that the cutting force and temperature increase with an increase in feed rate due to higher shear stress formation. Literature review shows that the machining of titanium alloy with CBN and PCD tools have been limited in turning process. Reddy et al - Finite Element Analysis and Modeling of Temperature Distribution in ... 61
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