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

Machining is one of the methods to produce components and products from raw material. Many factors influence the outcome of the machining process and the life of the components there after. Researchers have tried to understand the underlying principles of machining using finite element analysis since many years. In the present work the authors have made an attempt to study few behaviour namely, stress distribution, force variation and machining induced residual stresses while machining hard to machine Ti6Al4V alloy using finite element analysis. The model that is presented in this work is an improvisation of some of the existing models overcoming some of the shortcomings of the existing model. The work presented here uses the time tested Johnson-Cook model, but unlike the many other works sacrificial layers is not being used rather, Johnson-Cook damage model is being used. In addition, the authors have considered opted for oblique cutting in spite of high computational time due to the want of more accurate results