Optimization and finite element modeling of orthogonal turning of Ti6Al4V alloys: A comparative study of different optimization techniques

Abstract

The main goal of this research is to compare the various optimization strategies (Response Surface Methodology, Taguchi, and Teaching Learning Based Optimization) for orthogonal turning of Hard to Machine materials. The workpiece material in this work is Ti6Al4V alloys. After selecting cutting speeds in the High-Speed Machining range, orthogonal turning tests are performed on the material for a specific combination of machining parameters – Depth of Cut, Cutting Speed, and, Feed Rate. A Lathe Tool Dynamometer is used to record the cutting forces from the trials. After combining Johnson Cook Material and Damage models, a comprehensive Finite Element Model is created to model the Orthogonal Turning of Ti6Al4V alloys. Experiments conducted previously validate the developed model. Three different strategies, namely RSM, Taguchi, and TLBO, were used to optimise machining parameters for minimal Cutting Force. The approaches are compared for the best combination of machining parameters and the best Cutting Force value. Analysis of Variance is used to study the impact of machining factors on Cutting Force.