Computational and experimental investigation of cutting tool geometry in machining titanium Ti-6Al-4V

Modelling and simulation can significantly enhance the understanding of complex manufacturing processes. Finite element modelling has been increasingly used for modelling machining processes. Using FEM, cutting tool geometries can be investigated replacing the need for expensive experimental works leading to software defined manufacturing. In addition, they can help making informed and data driven decisions for planning machining experiments. There are limited studies on cutting tool geometries for machining titanium alloys, of those, mostly concentrated on experimental investigations. In this study, the impact of cutting tool rake angle on machinability of Ti-6Al-4V is investigated computationally and experimentally. Two levels of rake angle were used to model the cutting process. The Lagrangian formulation incorporating a Johnson-Cook (JC) material model, as well as energy-based ductile fracture criterion, were used to simulate the segmentation of chips. Machining experiments were conducted to assess the suitability and efficiency of finite element modelling for cutting tool design.