Numerical Modeling of Cutting Forces and Temperature Distribution in High Speed Cryogenic and Flood-cooled Milling of Ti-6Al-4V

Achieving high material removal rates in machining of Ti-6Al-4V alloy is challenging due this material's poor machinability. Thermally-activated tool-wear mechanisms limit tool-life and machining productivity. 3D Finite Element models were developed in DEFORMTM for cryogenic and flood-cooled milling in order to predict the cutting forces and thermal fields generated during machining. The same model was used to determine cutting speeds necessary for high material removal rates at temperatures below the ideal maximum for carbide tools. These simulations revealed that liquid nitrogen application in cryogenic machining reduced cutting temperature by 40%, allowing for longer tool-life and increased machining productivity. (C) 2019 The Authors. Published by Elsevier B.V.