Finite Element Analysis of the Milling of Ti6Al4V Titanium Alloy Laser Additive Manufacturing Parts

Abstract

This study aimed to analyze the defects of large residual stress in laser additive manufacturing metal parts by establishing a milling numerical simulation of Ti6Al4V titanium alloy thin-walled parts based on the Johnson-Cook constitutive model of Ti6Al4V titanium alloy, a modified Coulomb friction stress model, the physical chip separation criterion and other theories, combined with the finite element software ABAQUS. The influences of milling depth, initial temperature and milling speed on the forming quality of the formed part were analyzed. The results show that milling changes the residual stress distribution of the deposition layer, which can reduce or even change the residual tensile stress on the surface of the deposition layer produced by the additive manufacturing process into compressive stress, and the equivalent Mises stress decreases by 47% compared with the original forming surface. When the initial temperature increases from 20 °C to 400 °C, the maximum equivalent Mises stress of the milling surface decreases by 26%.

Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental Validation

“…Similarly, an increase in the feed rate obviously increases the cutting temperature sharply. A drastic rise in cutting temperature is observed with higher feed rates [49]. Increasing the depth of cut of machining increases the friction as more material is removed through shearing action which eventually increases the cutting temperature as illustrated in Figure 12.…”

Investigating the Impact of Declination Angle on the Side Milling Process of Additively Manufactured Ti6Al4V Using a 3D Milling Finite Element Model

“…The specific parameters for the Ti6Al4V alloy used in laser additive manufacturing parts were obtained based on the methodology described in reference [6]. Detailed information regarding these parameters can be found in Tables 1 and 2.…”

Dynamic mechanical properties of selective laser-melted AlSi10Mg lattice structures: experimental and numerical analysis with emphasis on Johnson-Cook model parameters

“…FEM studies have a great place in the literature and industry to solve the engineering problems which requires long efforts and costly experiments to perform. FE modeling of additively manufactured samples has also gained popularity, particularly in predicting the dynamic absorption properties [10,27,28] and machining performance [29][30][31][32]. By considering the effects of strain rate, temperature, and pressure on the material's response, Johnson-Cook material and damage model (J-C model) is well-suited for simulating and analyzing complex dynamic phenomena [33].…”