Finite Element Modeling for High Speed Machining of Ti-6Al-4V Using ALE Boundary Technology
A finite element model of HSM (High Speed Machining) process of Ti6Al4V was developed with Abaqus 6.10. The flow stress of Ti6Al4V is taken as a function of strain, strain rate and temperature. Considering the fact that the tool edge radius is relatively large in HSM of Ti6Al4V and significantly influences the mechanical behaviour, thus a new Arbitrary Lagrangian-Eulerian (ALE) boundary technology was incorporated into the finite element model to simulate the flowing material around the tool edge.The adoption of ALE boundary technology could avoid using the traditional chip separation criterias and element deletion method in the model, which at the same time results in the less excessive element distortion and computational time in comparison with traditional finite element models of cutting process. The simulation results of Cutting force and temperature close to the experimental values in an acceptable range could be obtained and a stagnant zone in front of the tool edge was successfully observed in this new developed model with large tool edge radius.
D. Lu et al., "Finite Element Modeling for High Speed Machining of Ti-6Al-4V Using ALE Boundary Technology", Applied Mechanics and Materials, Vols. 66-68, pp. 1509-1514, 2011