Finite element modelling to predict machining induced residualstresses in the end milling of hard to machine Ti6Al4V alloy

Machining is one of the methods to produce components and products fromraw material. Many factors influence the outcome of the machining processand the life of the components there after. Researchers have tried tounderstand the underlying principles of machining using finite elementanalysis since many years. In the present work the authors have made anattempt to study few behaviour namely, stress distribution, force variation andmachining induced residual stresses while machining hard to machineTi6Al4V alloy using finite element analysis. The model that is presented inthis work is an improvisation of some of the existing models overcomingsome of the shortcomings of the existing model. The work presented here usesthe time tested Johnson-Cook model, but unlike the many other workssacrificial layers is not being used rather, Johnson-Cook damage model isbeing used. In addition, the authors have considered opted for oblique cuttingin spite of high computational time due to the want of more accurate results.