Finite element modelling to predict machining induced residual stresses in the end milling of hard to machine Ti6Al4V alloy

Abstract

Machining is one of the methods to produce components and products from 
raw material. Many factors influence the outcome of the machining process 
and the life of the components there after. Researchers have tried to 
understand the underlying principles of machining using finite element 
analysis since many years. In the present work the authors have made an 
attempt to study few behaviour namely, stress distribution, force variation and 
machining induced residual stresses while machining hard to machine 
Ti6Al4V alloy using finite element analysis. The model that is presented in 
this work is an improvisation of some of the existing models overcoming 
some of the shortcomings of the existing model. The work presented here uses 
the time tested Johnson-Cook model, but unlike the many other works 
sacrificial layers is not being used rather, Johnson-Cook damage model is 
being used. In addition, the authors have considered opted for oblique cutting 
in spite of high computational time due to the want of more accurate results.