Modeling Cutting Forces in High Speed End-Milling of Titanium Alloys using Finite Element Analysis and Mechanistic Model

Abstract

Cutting forces are essential determinants in machining processes, and designing tools and fixtures necessary for production. Excessive cutting forces cause unacceptable large deformation of cutting tool, workpiece, and quality of the machined surface. They also have a major influence on the life of the machine tool. Therefore a sound knowledge of cutting forces and the effect of cutting parameter s on them is vital. This paper presents the results of 3-D finite element modeling and simulation of cutting forces in end-milling of titanium (Ti-6Al-4V) alloy workpiece used in aerospace industry. Simulations are done using carbide end-mills with varing corner radius, coated with TiAlN. Finite element modeling and simulations were performed using Thirdwave AdvantEdge software. The effects of spindle speed, feed per tooth, axial depth of cut, radial depth of cut, and corner radius were investigated using Taguchi L16 design of experiment. Mechanistic model of cutting forces for the same tool was developed and cutting forces predicted from this model were compare with the results obtained from finite elment analysis. End-milling experiments were conducted on Cincinati Milacron Sabre 750 Vertical Machining Center for validating the results obtained by the above two methods. Cutting forces were acquired using Kistler 4-component dynamom eter. The results and optimum machining parameters for machining titanium are presented.

Meeting Name

9th CIRP International Workshop on Modeling of Machining Operations (2006: May 11-12, Bled, Slovenia)

Department(s)

Mechanical and Aerospace Engineering

Keywords and Phrases

Cutting Forces; Machining Processes; Production

Document Type

Article - Conference proceedings

Document Version

Citation

File Type

text

Language(s)

English

Rights

© 2006 CIRP, All rights reserved.

Publication Date

12 May 2006

Link to Full Text

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