Modelling and Numerical Simulation of Cutting Stress in End Milling of Titanium Alloy using Carbide Coated Tool

Based on the cutting force theory, the cutting stress in end milling operation was predicted satisfactorily through simulation of using finite element method. The mechanistic force models were introduced in high accuracy force predictions for most applications. The material properties in the simulations were defined based on the cutting force theory, as a function of strain and strain rate whereas in the theoretical relationships, these properties were simply kept constant. According to the analysis, the maximum deformation and effective stress showed an increasing trend for the machining with end-milling cutting tool. A reasonable set of milling parameters for the machining of titanium alloy by coated cemented carbide cutting tool were obtained by analyzing the cutting efficiency in relation to cutting force of the tools. It is expected that this study would provide a fundamental basis for the optimization of the cutting parameters for titanium alloy.