Simulation, analysis and comparison of cutting parameter during turning of Ti-6Al-4V alloy with assorted industrial coated carbide

Abstract

This work focuses on studying the special effects of processing conditions on the J-C (Johnson-Cook) material model factors for orthogonal turning of Ti-6Al-4V. It is highly corrosive resistant materials. Two sets of factors of the Johnson-Cook material model describing material behavior of both alloy were investigated by comparing cutting forces, chip study, and chip tool interfaces temperature. A 2-D finite element model was made and validated with the results of published literature. Cutting tests were conducted at low, medium, and high-speed cutting speeds with three different cutting tools. Chip formation and cutting forces were compared for both numerical models. It was observed that cutting forces decrease as cutting speed increases. Three different types of cutting tools are used here with the same geometry so that the result can be compared attractively. The results are then compared with experimental references and more standard models: an ALE model developed with ABACUS (FEA software). It was observed that the Polycrystalline Diamond tool produces less force as compared to other tools. The results obtained through simulation analysis after including changes in the coefficient of friction and other material properties showed a good agreement with the experimental results.