Title: Optimisation of machining TI6AL4V alloy: numerical simulation and experimental verification

Authors: Alaa H. Jaafar; Haydar Al-Ethari

Addresses: Department of Metallurgical Engineering, University of Babylon, Hilla 51001, Iraq ' Department of Metallurgical Engineering, University of Babylon, Hilla 51001, Iraq

Abstract: The Ti6Al4V alloy is widely used in biomedical applications due to its good biocompatibility, low density, high corrosion resistance and high strength. The machining of this alloy poses several difficulties due to its unique mechanical properties and cutting characteristics. In the present study, a series of finite element simulations based on DEFORM-2D software were run and combined with response surface methodology in order to improve machining performance characteristics, i.e., cutting temperature, main cutting force and surface roughness of Ti6Al4V alloy by optimising the cutting parameters (viz. cutting velocity and feed rate) and tool geometry (viz. cutting edge radius and rake angle). Analysis of variances was employed to investigate the influence of cutting parameters and tool geometry on the machining properties. Mathematical models were developed to predict the responses. Finally, experimental verification was performed to check the validity of the numerical model that predicted responses within 8.4% maximum error.

Keywords: Ti6Al4V; DEFORM-2D; optimisation; machining; response surface methodology; RSM; design of experiments; ANOVA; cutting temperature; main cutting force; surface roughness.

DOI: 10.1504/IJMMM.2018.096055

International Journal of Machining and Machinability of Materials, 2018 Vol.20 No.5, pp.447 - 459

Received: 28 Dec 2017
Accepted: 19 May 2018
Published online: 09 Nov 2018 *

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