Modeling and FE Simulation of tool wear mechanism in single point turning of Titanium alloy i.e. Ti6Al4V under various conditions

Abstract

With the advancement of computer hardware and readily available commercial Finite Element software, the application of simulation is on the increase in every other aspect of our life. In the manufacturing industry, machining is one of the most important processes, has also undergone the same phenomena. By using the finite element analysis software, and applying the available technical knowledge, one can oversee many hurdles that might be faced in the actual machining process. Many commercial FEA software packages are available in the market which utilizes the readily available computational power to simulate the machining process. Due to limitations in the available resources in terms of theoretical/experimental knowledge and multiple variables involved in the machining process, the results of the simulation might not match entirely with the actual results quantitatively. But these results can lead to an enhanced understanding of the effects of varying various machining parameters on the outcome of the various machining techniques. It is pertinent to mention that there are still numerous obstacles in the accurate simulation-based design of the machining process before it can be adopted in routine by the industry. Single point turning operation of Titanium alloy i.e Ti6AL4V under various cutting conditions is simulated. Various factors affecting the machining of the titanium alloy are studied and simulated in FE analysis. The FEA software chosen for the numerical investigation of Titanium alloy machining is ABAQUS. From multiple options available in the software, Johnson-Cook (JC) fracture material model based upon the energy method is selected.