Effect of cutting edge radius on cutting force and surface roughness in machining of Ti-6Al-4V
Kejia Zhuang, Jinqiang Gao, Ye Tao, Xing Dai
Abstract
This study aims to investigate the effect of cutting edge radius on surface roughness in orthogonal cutting of Ti6Al4V based on numerical simulation. A finite element model is established to model the machining-induced surface roughness using a Coupled Eulerian-Lagrangian (CEL) method. The CEL method can be used to simulate the elastic recovery on machined surface, and the surface topography in cutting speed direction can be achieved. Then, the impact of mesh size on numerical force and surface morphology is discussed, and it is concluded that fine mesh has better performance in force and surface roughness prediction. The significant influence of edge radius on feed force and surface roughness can be noted through simulations with fine mesh, that is, a larger edge radius can provide larger feed force and rougher machined surface. Finally, the effectiveness and correctness of proposed model are validated by orthogonal cutting experiments of Ti6Al4V.