The effect of rake angle and feed rate on the machining process of Ti6Al4V, a study using Finite Element Method

Abstract Ti6Al4V is a used in various engineering application, such as aerospace, automotive, and chemical, because of its strength ratio to weight advantage. Ti6Al4V requires relatively complex processing because of the material’s mechanical properties, so research related to the processing of Ti6Al4V is needed to create a reference in its processing. This research aims to simulate the machining process with a finite element method to achieve lower cost and efficient research time compared to direct experiments. Cutting simulation was conducted as orthogonal 2D with the Johnson-Cook material and Johnson-Cook damage models. This research aimed to predict the final results of variables simulated stress, temperature, chip formation, and cutting force. Simulated rake angle variated by 0°, 7°, 14° and feed rate 0.08, 0.1, 0.15 mm/rev with cutting speed 40 m/min and width of cut 2 mm. Maximum stress 1342 N was achieved at feed 0.08 with rake angle 7° and maximum temperature noted 534°C at feed 0.15 mm/rev with rake angle 0°, while maximum cutting force reached 700 N at feed 0.15 mm/rev with rake angle 0°. Chip formation formed in this simulation mainly consisted of serrated chips in variation above 0° rake angle, and more segmented serrated chips formed when the rake angle increased positively.