Finite element modeling for the cutting process of the titanium alloy Ti10V2Fe3Al.

By producing of critical components in the aerospace industry is widely used the β-titanium alloy Ti10V2Fe3Al (Ti-1023) due to its extremely high ratio of strength to density, its great resistance to fatigue, its excellent resistance to corrosion and fracture toughness. This material is characterized by significant difficulties in machining. Substantial assistance in the study of the titanium alloy Ti-1023 machinability can provide a simulation of machining by numerical modeling. This paper presents the results regarding the creation of the FEM models for the cutting processes of the titanium alloy Ti-1023. The created FEM cutting models were constantly verified with experimental tests of the kinetic machining characteristics and analyses of the chip morphology by orthogonal and oblique cutting as well as flat end milling with different depths of immersion. A Johnson-Cook model was used as material model of the workpiece and the damage mechanism of the workpiece is reproduced with the Cocroft and Latham model. The parameters of material and fracture model were determined by DOE study. Comparing the experimentally established and the simulated kinetic machining characteristics and chip morphology confirms that the created FEM models are of a good quality. The size of error for simulating the chip dimensions does not exceed 10 % and ranges between 10 and 30 % for simulating the resultant forces. [ABSTRACT FROM AUTHOR]