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The development of reliable numerical tools for predicting the machined surface integrity has become of primary importance nowadays. This paper introduces a novel customized FE model to predict microstructural changes generated during turning of the Electron Beam Melted (EBM) Ti6Al4V alloy under dry cutting and cryogenic cooling. The material peculiar fine acicular microstructure and the nano-hardness variation are modelled and implemented into a FE model by means of a User Subroutine. The developed FE model permits to predict the microstructure (alpha lamellae thickness), the plastic deformation (alpha lamellae deformation) and nano-hardness variations induced by machining operation under dry and cryogenic conditions. [ABSTRACT FROM AUTHOR]

Nowadays, numerical modeling is becoming a valuable and powerful tool for designing and optimizing the production process, as well as improving the machined components quality. Particularly, the Finite Element Method permits to increase the knowledge on the machinability of difficult-to-cut metals, such as the titanium alloys. The aim of this work is to develop a 3D FE model as a tool for predicting cutting forces, temperature, and machining-induced microstructural alterations during semi-finishing turning Ti6Al4 V under dry and cryogenic conditions. The numerical model is experimentally calibrated and validated. [ABSTRACT FROM AUTHOR]