Numerical and Experimental Analysis of Residual Stresses Generated in the Machining of Ti6Al4V Titanium Alloy

Abstract

This paper presents 2D and 3D FEM simulation results concerning the distribution of residual stresses in the sublayer of machined parts made of Ti6Al4 V titanium alloy. FEM simulations were performed for power law and J-C (Johnson-Cook) material constitutive models. Machining tests were carried out using carbide cutting tools coated with a TiAlN monolayer without coolants. The selection of machining conditions was based on real production data. In addition,a real CAD model of the cutting tool insert was implemented. Moreover, an advanced technique of meshing the cutting edge and the grooved rake face was applied. Residual stresses in the machined parts were measured using X-ray diffraction technique. Finally, FEM simulations were compared with measurements in order to recommend the best simulation strategy.