Optimization of numerical parameters in machining of Ti alloy

Abstract

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Numerical models applied to the machining of titanium alloys are essential tools in the aerospace industry, as they help reduce the need for extensive and costly experimental trials while enabling precise analysis of complex machining phenomena. This work focuses on the optimization of numerical parameters in a finite element model of high-speed orthogonal cutting applied to Ti6Al4V, using the Abaqus software. Particular attention is given to the influence and calibration of numerical parameters (such as mesh size and mass scaling factor), along with tribological (friction at the tool/chip interface) and material-related parameters (fracture energy of the workpiece material), over a wide range of cutting speeds. The objective is to enhance the reliability and accuracy of the model in predicting key machining outputs such as cutting forces, chip morphology and temperature distribution, including the peak temperatures generated during the process. By optimizing the numerical and material parameters, we achieved a relative error on cutting forces below 11% across all cases when comparing our model predictions to the full set of experimental data from the literature presented her