High-Speed Machining Process of Titanium Alloy: A Comprehensive Finite Element Modeling

This study comprehensively deals with a two-dimensional finite element (FE) modeling and simulation for chip formation process of titanium alloy. The basic parameters, such as chip shape, workpiece surface, equivalent stress, plastic strain and cutting force, are analyzed to study the impact of a variety of rake angles during high-speed machining. The chip shapes vary with the tool-rake angle. During the serrated chip formation, the primary deformation region exhibits substantially higher stress than secondary region. Also, the higher strains are occurred at the chip roots. The fluctuation of the cutting force caused by the serrated chip is more prominent than that obtained during the continuous chip formation, and the force varies periodically. The results also show that an increase in the positive direction of rake angle causes a decrease in cutting force and a smoother workpiece surface.