On the Flow Stress Model selection for Finite Element Simulations of Machining of Ti6Al4V

Numerical simulation of machining processes represents a promising tool able to reproduce the cutting conditions without the need to perform a large number of experimental tests. In order to obtain reliable results from the finite element method simulation, is then necessary to properly set up the simulation conditions and to implement the most suitable material's behavior according to the real workpiece characteristics. These data are available in commercial software's libraries but often they have difficulties to properly represent the machined workpiece behavior. Thus, advanced model are implemented in the software to improve the simulations performance and to obtain realistic results. In this work, the more suitable material's flow stress, within those proposed in literature, is sought to simulate the machining process of Ti6Al4V. The results of the simulations have been compared with those obtained experimentally in terms of temperature, chip morphology and cutting force. The results confirm the need to properly select the material's flow stress model according to the physical sample.