Influence of Coulomb’s Friction Coefficient in Finite Element Modeling of Orthogonal Cutting of Ti6Al4V

The reliability of the pertinent parameters set of Johnson-Cook constitutive model is highly linked with the friction condition at the tool-chip-workpiece interface. In the present work, a study on the influence of Coulomb’s friction coefficient on the observables such as forces, chip thickness and chip curvature by FE simulation of orthogonal cutting of Ti6Al4V alloy has been carried out. A FE model with an Arbitrary Lagrangian-Eulerian (ALE) approach is employed to simulate the cutting process for different cutting conditions. The simulated results, for a wide range of friction conditions, are analyzed and compared with experimental results. The analysis show that the Coulomb’s friction coefficient has a direct link with the observables. The paper reveals that for accurate prediction of observables an optimized value of the coefficient of friction in correlation with the parameters values of the constitutive model is imperative.