Effects of cutting conditions on the cutting forces in machining additively manufactured Ti6Al4V alloy

School of Engineering, Robert Gordon University, Garthdee Road, Garthdee, Aberdeen, United Kingdom, AB 10 7GJ.

^* Corresponding author: m.younas@rgu.ac.uk

Abstract

Machining of additive manufacturing (AM) process results in excessive consumption of the cutting power due to the high strength and hardness of the material produced that led to high cutting forces and short tool life during machining process. This paper aims to investigate the effect of cutting conditions and coefficient of friction on the cutting forces, during finite element analysis (FEA) of an orthogonal cutting of AM Ti6Al4V alloy bar. The FEA simulation considers three different experiments at low, medium, and high cutting conditions. The result shows that as the depth of cuts gets deeper and the cutting speed increases, the cutting forces were found to increase, leading to serrated or segmented chips formation. A cutting force of 1300.36N was observed at a cutting speed of 150 m/min and a coefficient of friction of 0.9. The cutting force was found to be weaker at the higher shear plane angle of 42.2^o and higher at a smaller angle of 37.57^o. The coefficient of friction was observed to be insignificant at lower value of 0.09 and was seemed to affect the cutting force at value around 1.