Hot machining of Ti-6Al-4V: FE analysis and experimental validation

Machining process is a nonlinear process where high stress, temperature and strain are generated in the primary and secondary shear zone. It is difficult to determine these parameters experimentally and also consumes time. In this study, finite-element method (FEM) is applied to hot machining of Ti-6Al-4V alloy using DEFORM software. The simulations are used to investigate the effect of heating temperature on cutting force, cutting temperature, stress, strain and chip morphology for various machining conditions. The predicted results are compared to results obtained in room temperature and hot machining conditions. From this analysis, it is observed that hot machining reduces the cutting force, and changes the chip morphology. To validate the simulation results, an experimental trial is performed and positive coherence is achieved.