3D Finite Element Simulation of Orthogonal Cutting of Ti–6Al–4V Using Textured Tool

Ti–6Al–4V alloy is widely used in various industries due to its significant properties. However, due to its poor machinability characteristics, Ti–6Al–4V is classified as a difficult to cut material. The incorporation of surface texturing on the tool faces improves the tribological properties which in turn enhances the overall machinability of the alloy. In this paper, 3D finite element simulation of the orthogonal cutting of Ti–6Al–4V workpiece performed using innovative texture patterns to improve the machinability has been adopted. The stresses induced at the work surface while machining with various textured tools as well as conventional tools have been investigated and compared with the ANSYS WORKBENCH software. The results showed a significant reduction in stress values induced at the work surface while machining with tools having combined textures of both dimples and linear groove patterns.