Three-dimensional finite element modeling of high-speed end milling operations of Ti-6Al-4V

This article presents the development of a three-dimensional finite element model to simulate the high-speed end milling of Ti-6Al-4V titanium alloy based on the commercial finite element package Abaqus/Explicit. The Johnson–Cook material constitutive model was employed to model the flow stress behavior of the workpiece. Zorev’s friction model was used to determine the frictional behavior of the tool–chip interface, and Johnson–Cook shear failure criterion was used to realize chip separation. Based on the three-dimensional finite element model, cutting forces in three directions were predicted under different cutting conditions, and chip evolution and morphologies of different cutting parameters were also analyzed. Corresponding high-speed end milling tests were conducted, and cutting forces were measured using a piezoelectric dynamometer in order to validate the finite element model. The simulation results demonstrate an acceptable agreement with experimental results in both the chip morphologies and cutting forces in the range of cutting speed and feed rates considered.