Finite Element Simulation Of Cutting Force In High Speed Cutting Of Ti-6al-4v Alloy

High speed machining technology is one of the most orientation in advanced manufacturing technology. With widespread use of titanium alloys in various industries ,high speed machining of titanium alloys is always one of the very complicated problems in aircraft, spacecraft and other manufacturing industries During high speed machining of titanium alloys ,the cutting force is the essential to calculate cutting twist moment and power and it is basis to analyze generation of heat tool wear ,using life machining precision and surface quality of the cut surface .This dissertation focuses on cutting force during high speed cutting Ti-6Al-4V alloys by finite element method with commercial software ABAQUS .First of all, according to the characteristic of high speed machining,formation mechanism of cutting zone,forces of chip suffering , friction characteristic of tool-chip ,constitutive model ,fracture criterion etc. Next, according to the theory of orthogonal cutting ,the three-dimensional model of milling is simplified to the mode of two-dimensional orthogonal metal cutting .Then ,the model of geometry and material is established .The pure Lagrange boundary of ALE model is used to simulate the cutting of Ti-6Al-4V by analyzing two different ALE models with the result of experiment .Next , cutting force changing with single cutting parameters is analyzed during high speed cutting Ti-6AI-4V alloys ,mainly including the speed of cutting ,feed ,tool edge radius and the model of friction. Experimental formula is set up with the finite orthogonal test of four factors at three different levels in high speed cutting of Ti-6Al-4V alloy .It can reliably predict the cutting force of orthogonal cutting Ti-6Al-4V alloys in high speed .It plays significance to the manufacture of titanium alloy with high efficient and low cost.