Abstract
When machining the titanium alloy Ti6Al4V, segmented chip formation is a major challenge as it leads to chatter-vibrations of the tool-machine-system. In this paper a counter element to suppress segmentation, the constraint, is designed by simulations. Therefore, the segmented chip formation of Ti6Al4V has been modelled in a finite element simulation using different approaches for flow stress modelling. The simulation results were validated with the help of orthogonal cutting experiments. Based on a suitable choice of a flow stress model, different geometries and positions of the constraint are analysed and discussed in this paper.
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