Abstract
The Ti6Al4V alloy is widely used in biomedical applications due to its good biocompatibility, low density, high corrosion resistance and high strength. The machining of this alloy poses several difficulties due to its unique mechanical properties and cutting characteristics. In the present study, a series of finite element simulations based on DEFORM-2D software were run and combined with response surface methodology in order to improve machining performance characteristics, i.e., cutting temperature, main cutting force and surface roughness of Ti6Al4V alloy by optimising the cutting parameters (viz. cutting velocity and feed rate) and tool geometry (viz. cutting edge radius and rake angle). Analysis of variances was employed to investigate the influence of cutting parameters and tool geometry on the machining properties. Mathematical models were developed to predict the responses. Finally, experimental verification was performed to check the validity of the numerical model that predicted responses within 8.4% maximum error.
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