Research in Engineering and Aviation

3D Numerical Investigation of Effects of Milling Process Parameters on High Speed Milling of TiAl6V4

November 2012

Author(s): J. Ma, S. Lei, H. Lu

ASME IMECE 2012-88235. ASME 2012 International Mechanical Engineering Congress & Exposition. November 9-15, 2012, Houston, Texas, USA.

Abstract

Titanium alloys are widely used in aerospace industry owing to excellent mechanical properties. While because of high chemical reactivity and low thermal conductivity, titanium alloys are classified as hard-to-cut materials. In this paper, Finite Element Method (FEM) is employed to conduct numerical investigation in the effects of milling process parameters (milling speeds, feed per tooth, and axial depth of cut) on three-dimensional (3D) high speed milling of Titanium alloy (Ti-6Al-4V). The tool material used is Carbide and Johnson-Cook plastic model is employed to model the workpiece due to its capability of modeling large strains, high strain rates, and temperature dependent visco-plasticity. Different milling speeds, feed per tooth, and axial depth of cut are used to explore the effects of the milling process parameters on the cutting temperature, cutting forces, and power required for machining. This model provides fundamental understanding of cutting mechanics of the 3D high speed milling of Titanium alloy (Ti-6Al-4V).