Abstract:
To minimize experimental time and expensive experimental test, researchers always refer FEA as most effective system. In this paper, we tried to show the effect of rake angle, cutting speed in chip morphology for different materials. We structured a finite element model for predicting chip morphology in different cutting conditions and then we validated our model with comparison to established papers. Orthogonal cutting methodology has been adopted for analysis. As we know Ti-6Al-4V is most commercially available Titanium alloy. Among the uses of Titanium alloy, 50% of industry uses Ti-6Al-4V. This material is widely known as high strength-weight ratio and excellent corrosion resister. It has 40% lesser density than steel and also having workability at high temperature (600degree).But it has machining problem due to low thermal conductivity and chemically reactivity and our model was able to predict effect of rake angle and effect of cutting speed as well as helped to find out critical rake angle of this material. Our model was able to predict chip type properly and also temperature in the cutting zone and cutting and tangential forces associated to the cutting condition. Every cutting parameter were set from established research works and material specification has been taken from material different material handbook and it has been shown that our FEA model is correct and validates multiple research work with same model in most cases with marginal error.
