Investigation of Cutting Parameters of Drilling Ti6Al4V Using Finite Element Analysis

Abstract

The high strength, low weight ratio and outstanding corrosion resistance of Ti6Al4V led to wide range of applications which demand
high levels of reliable performance in aerospace, automotive, chemical plant, power generation and other major industries. Ti6Al4V also has
numerous applications in the medical industry. The biocompatibility of Ti6Al4V is excellent, especially when direct contact with tissue or
bone is required. However, these alloys are notoriously difficult to machine owing to several inherent properties of the material. Drilling is
one of the most widely used machining technique in industry and there are lots of studies to investigate in both academic and industrial area.
Predictions of important process variables such as temperature, cutting forces and stress distributions play significant role on designing tool
geometries and optimizing cutting conditions. Researchers find these variables by using experimental techniques which are time consuming
and expensive. As an alternative, Finite Element Modelling (FEM) becomes main solution. Heat generation during a drilling process has a
major influence on the tool life and workpiece material behavior that are significantly affected by cutting conditions (cutting speed, feed
rate). In this study, the effect of cutting conditions on temperature generated in drilling process was investigated by means of finite element
simulations using DEFORM-3D. Variation of temperature on Ti6Al4V workpiece was examined with respect to change in feed rate (0.2, 0.3,
0.4 mm/rev) and cutting speed (2000, 3000 rpm) cutting conditions. In all of these simulations, workpiece material has 1 mm height, 2 mm
radius cylindrical shape and 10 mm length WC drill bit, designed using Catia program, were used.