Determination of Specific Forces and Tool Deflections in Micro-milling of Ti-6Al-4V alloy using Finite Element Simulations and Analysis

Journal Article · Wed May 04 00:00:00 EDT 2011 · AIP Conference Proceedings

DOI:https://doi.org/10.1063/1.3589588· OSTI ID:21516771

Farina, Simone; Ceretti, Elisabetta ^[1]; Thepsonti, Thanongsak; Oezel, Tugrul ^[2]

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1. University of Brescia, Department of Mechanical and Industrial Engineering (Italy)
2. Rutgers University, Department of Industrial and System Engineering, New Jersey (United States)

Titanium alloys offer superb properties in strength, corrosion resistance and biocompatibility and are commonly utilized in medical devices and implants. Micro-end milling process is a direct and rapid fabrication method for manufacturing medical devices and implants in titanium alloys. Process performance and quality depend upon an understanding of the relationship between cutting parameters and forces and resultant tool deflections to avoid tool breakage. For this purpose, FE simulations of chip formation during micro-end milling of Ti-6Al-4V alloy with an ultra-fine grain solid carbide two-flute micro-end mill are investigated using DEFORM software.At first, specific forces in tangential and radial directions of cutting during micro-end milling for varying feed advance and rotational speeds have been determined using designed FE simulations for chip formation process. Later, these forces are applied to the micro-end mill geometry along the axial depth of cut in 3D analysis of ABAQUS. Consequently, 3D distributions for tool deflections and von Misses stress are determined. These analyses will yield in establishing integrated multi-physics process models for high performance micro-end milling and a leap-forward to process improvements.

• OSTI ID: 21516771
• Journal Information: AIP Conference Proceedings, Vol. 1353, Issue 1; Conference: ESAFORM 2011: 14. international ESAFORM conference on material forming, Belfast, Northern Ireland (United Kingdom), 27-29 Apr 2011; Other Information: DOI: 10.1063/1.3589588; (c) 2011 American Institute of Physics; ISSN 0094-243X
• Country of Publication: United States
• Language: English

Related Subjects

36 MATERIALS SCIENCE
ALUMINIUM ALLOYS
CARBIDES
CORROSION RESISTANCE
CUTTING
DISTRIBUTION
FABRICATION
FINITE ELEMENT METHOD
MANAGEMENT
MANUFACTURING
MILLING
PERFORMANCE
SIMULATION
SOLIDS
STRESSES
TITANIUM ALLOYS
TOOLS
VANADIUM ALLOYS
ALLOYS
CALCULATION METHODS
CARBON COMPOUNDS
EQUIPMENT
MACHINING
MATHEMATICAL SOLUTIONS
NUMERICAL SOLUTION
TRANSITION ELEMENT ALLOYS