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Simulation machining of titanium alloy (Ti-6Al-4V) based on the finite element modeling

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Abstract

Titanium alloy is the most significant material used in the aviation industry because of their properties such as high strength and corrosion resistant. However, it is considered one of the most challenging areas for all industrialists due to their poor machinability. Therefore, machining process needs to be controlled by selecting the optimal cutting conditions to obtain the best machining responses at the same time which is very difficult and involves high cost. Hence, this review paper presents the investigation of an agreement between the simulation results and experimental findings to evaluate the finite element modeling (FEM) for prediction of the machining parameters of titanium alloy (Ti-6Al-4V). Computer-aided engineering tools, especially software which was used to perform the simulation. Four types of finite element software have been focused during the machining process of titanium alloy (Ti-6Al-4V) such as AdvantEdge, ABAQUS/EXPLICIT, DEFORM, and FORG software. The simulation results of FEM proved an agreement with the experimental data during the machining process of titanium alloy (Ti-6Al-4V). The FEM permits to reduce the cost of manufacturing in terms of prolonging the cutting tool life and saving machining time.

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Abbreviations

A :

Initial yield stress (MPa)

B :

Hardening modulus (MPa)

C :

Strain rate dependency coefficient (MPa)

d :

Depth of cut (mm)

f :

Feed rate (mm/min)

F c :

Cutting force (N)

F t :

Feed force (N)

m :

Thermal softening coefficient

n :

Work-hardening exponent

v c :

Cutting speed (m/min)

γ :

Rake angle (deg)

α :

Clearance angle (deg.)

σ :

Flow stress

ε ρ :

Strain

ε :

Strain rate

ε o :

Reference strain rate (1/s)

σ :

Stress (Von-Mises)

T r :

Room temperature

T m :

Melting temperature

FEM:

Finite element modeling

J–C:

Johnson–Cook model

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Acknowledgments

The authors would like to acknowledge all the researchers who were mentioned in their research. We respect and appreciate all of them. The authors are grateful to the Universiti Tenaga Nasional, Malaysia and University of Babylon, Iraq in carrying out this research work.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Tenaga Nasional Universiti, Putra Jaya campus, 43000, Kajang, Malaysia

    Moaz H. Ali

  2. University of Babylon, Babylon, Iraq

    Moaz H. Ali

  3. Department of Mechanical Engineering, Tenaga Nasional Universiti, 43000, Kajang, Malaysia

    M. N. M. Ansari

  4. Sulaymaniyah Technical College, Sulaymaniyah, Iraq

    Basim A. Khidhir

  5. Universiti Teknikal Malaysia, Durian Tunggal, Malaysia

    Bashir Mohamed

  6. University of Malaya, Kuala Lumpur, Malaysia

    A. A. Oshkour

Authors
  1. Moaz H. Ali
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  2. M. N. M. Ansari
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  3. Basim A. Khidhir
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  4. Bashir Mohamed
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  5. A. A. Oshkour
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Correspondence to Moaz H. Ali.

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Technical Editor: Alexandre Abrão.

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Ali, M.H., Ansari, M.N.M., Khidhir, B.A. et al. Simulation machining of titanium alloy (Ti-6Al-4V) based on the finite element modeling. J Braz. Soc. Mech. Sci. Eng. 36, 315–324 (2014). https://doi.org/10.1007/s40430-013-0084-0

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  • DOI: https://doi.org/10.1007/s40430-013-0084-0

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