L Orthogonal Array-Based Three-Dimensional Finite Element Modeling For Cutting Force and Chip Formation Analysis During Dry Machining of Ti - 6Al-4V

Journal of Advanced Manufacturing Systems
Vol. 20, No. 1 (2021) 123–134

.c World Scienti¯c Publishing Company
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DOI: 10.1142/S0219686721500074
by UNIVERSIDADE FEDERAL DE SAO CARLOS on 07/07/23. Re-use and distribution is strictly not permitted, except for Open Access articles.
L16 Orthogonal Array-Based Three-Dimensional Finite

Element Modeling for Cutting Force and Chip Formation
Analysis During Dry Machining of Ti–6Al–4V
J. Adv. Manuf. Syst. 2021.20:123-134. Downloaded from www.worldscientific.com
Raviraj Shetty*
Department of Mechanical & Manufacturing Engineering
Manipal Institute of Technology
Manipal 576104, Karnataka, India
rr.shetty@manipal.edu
Sanjeev Kumar
Mechanical Engineering Department
Government Polytechnic, Belagavi, India
Ravindra Mallagi
Product Design and Manufacturing
Visvesvaraya Technological University, Belagavi, India
Laxmikanth Keni
Aeronautical and Automobile Engineering
Manipal University, Manipal, Karnataka, India
The outstanding characteristics of titanium alloy (Ti–6Al–4V) have made this material
applicable in aerospace and medical components. However, due to its poor machinability
characteristics, researchers are forced to understand the machinability behavior of Ti–6Al–4V.
In this paper, L16 orthogonal array-based three-dimensional ¯nite element modeling for the
cutting force and chip formation analysis during the machining of Ti–6Al–4V using cubic boron
nitride tool in dry turning environment has been investigated. The ¯nite element simulation was
performed using ANSYS Workbench, version 19.0. Cutting force and chip formation were
investigated using the results obtained from L16 orthogonal array-based three-dimensional ¯nite
element modeling. This research would help to identify the optimum cutting conditions and
minimize the cutting force followed by analyzing the types of chips formed during machining
under the selected set of cutting conditions.
Keywords: Ti–6Al–4V; cutting force; chip formation; L16 orthogonal array; FEM.
1. Introduction
Since 1950, the outstanding characteristics of titanium alloys compared to other
conventional metals in terms of physical, mechanical and biological performances
*Corresponding author.
123
124 R. Shetty et al.
have led to their application in the ¯elds of aerospace, automobile, medical and
aircraft.1–4 However, during machining, the chemical reaction of titanium alloy on
the cutting tool material at high cutting temperatures resulting in rapid tool wear is
of major concern.5 Reference 6 suggested that Taylor's empirical equations do not

hold good for the machining of titanium alloy due to the involvement of only cutting
speed. Hence, it is necessary to investigate the machinability characteristics of ti-
tanium and its alloys. Today, numerical modeling and ¯nite element method (FEM)
have become powerful tools applicable in a variety of applications.7 Reference 8
suggested that FEM is a tool used during machining for the prediction of chip types,
temperature distribution and cutting forces generated. Reference 9 carried out
thermomechanical analysis during orthogonal cutting at the primary deformation
zone. Reference 10 studied the stress distribution using ¯nite element method. They
concluded that particle debonding, displacements and inhomogeneous deformation
of the matrix material resulted in more stress during the machining of DRACs.
Reference 11 adopted ¯nite element analysis to understand the chip formation
mechanism during the machining of DRACs. Reference 12 developed FEM model
for the prediction of cutting forces during dry micro-turning of titanium alloy. There
are many factors that a®ect the prediction accuracy of cutting simulation, such as
the physical parameters of the tool, workpiece, friction behavior between tool and
the chip and the plastic and failure parameters of the workpiece.13–16 Reference 17
adopted ¯nite element analysis, Taguchi's Design of Experiments (DOE) and re-
sponse surface methodology for stress distribution in the primary and secondary
deformation zones in the machining of DRACs using L27 orthogonal array. During
the machining of traditional engineering materials, Taguchi's method has been a
new methodology applied for obtaining an objective conclusion with the minimum
number of experiments and to solve the problem much faster.18–23 The research on
cutting force and chip formation mechanism has been the easiest way for under-
standing the machinability characteristics of any metals and alloys. Hence, this
paper deals with L16 orthogonal array-based ¯nite element analysis for the predic-
tion of machining process output variables.
2. Methodology
The Ti–6Al–4V having the chemical composition shown in Table 1 has been used for
¯nite element simulation. Table 2 shows the mechanical properties of the titanium
alloy Ti–6Al–4V. Cubic boron nitride (CBN) tool was the cutting tool material with
Table 1. Chemical composition of Ti–6Al–4V.24
Element Al V Fe O C N Y H Ti
wt.% 6.1 4 0.16 0.11 0.02 0.01 0.001 0.001 Bal.

L16 Orthogonal Array-Based Three-Dimensional Finite Element Modeling in Ti–6Al–4V 125
Table 2. Mechanical properties of the titanium

alloy Ti–6Al–4V.24
Property Typical value

Hardness (Rockwell scale) 30

Ultimate tensile strength (MPa) 955
Yield tensile strength (MPa) 900
Modulus of elasticity (GPa) 113.8
Poisson's ratio 0.342
Density (g/cm3 Þ 4.51
Elongation in 4D (%) 18
Reduction of area (%) 42
Fatigue strength (MPa) 240
Table 3. Levels and factors.
Cutting speed Depth of cut Rake angle Clearance angle Nose radius
Trial no. (m/min) (A) (mm) (B) (deg) (C) (deg) (D) (mm) (E)
1 100 0.10 5 4 0.010

2 150 0.15 0 5 0.015
3 200 0.20 5 6 0.020
4 300 0.30 10 7 0.030
four di®erent rake angles, clearance angle and nose radius. L16 orthogonal array is a
technique obtained from Taguchi's DOE used to design and analyze complicated
experiments without requiring the knowledge of statistics. The L16 orthogonal array
is used to formulate the experimental layout and to analyze the e®ect of each cutting
parameter in order to reach the optimum conditions. The L16 orthogonal array is
carried out by using the MINITAB software. The levels and experimental layout
chosen are summarized in Tables 3 and 4, respectively.
In ¯nite element modeling, temperature-independent plastic–kinematic material
model (from ANSYS Workbench, version 19.0) and Cowper–Symonds model have
been adopted.25 The yield stress has been calculated by the following equation:
:
" 1=P
y ¼ 1 þ ð0 þ Ep " eff
p Þ; ð1Þ
C

Etan E
EP ¼ ; ð2Þ
E Etan
:
where y is the yield stress, 0 denotes the initial yield stress, " is the strain rate, P
represents the Cowper–Symonds strain rate, " eff p is the e®ective plastic strain,
represents the hardening parameter, Ep is the plastic hardening modulus, Etan
denotes the tangent modulus and E is the modulus of elasticity.
The material properties of Ti–6Al–4V work material are 0 ¼ 125 MPa and
E ¼ 113:8 GPa and the values of Cowper–Symonds strain rate parameters are C ¼
Table 4. Control factor settings as per L16 orthogonal array.
Cutting speed Depth of cut Rake angle Clearance angle Nose radius
Trial no. (m/min) (A) (mm) (B) (deg) (C) (deg) (D) (mm) (E)
1 100 0.10 5 4 0.010

2 100 0.15 0 5 0.015
3 100 0.20 5 6 0.020
4 100 0.30 10 7 0.030
5 150 0.10 0 6 0.030
6 150 0.15 5 7 0.020
7 150 0.20 10 4 0.015
8 150 0.30 5 5 0.010
9 200 0.10 5 7 0.015
10 200 0.15 10 6 0.010

11 200 0.20 5 5 0.030
12 200 0.30 0 4 0.020
13 300 0.10 10 5 0.020
14 300 0.15 5 4 0.030
15 300 0.20 0 7 0.010
16 300 0.30 5 7 0.020
Fig. 1. Finite element mesh for Ti–6Al–4V work material and CBN tool.
Fig. 2. Finite element simulation with ¯xed support and displacement.

6500 and P ¼ 0. The element used is SOLID185 for the three-dimensional modeling
of tool and workpiece. The tool was constrained to move along the cutting direction
(X-direction) with velocities of 100, 150, 200 and 300 m/s and for the depths of cut
(Y -direction) of 0.10, 0.15, 0.20 and 0.3 mm. The tool was modeled as a rigid body
because of the signi¯cantly high modulus of the CBN tool material. Workpiece was
modeled as a rectangle and the tool was modeled for di®erent rake angles of 5 , 0 ,
5 and 10 and clearance angles of 4 , 5 , 6 and 7 , followed by the nose radii of 0.01,
0.015, 0.02 and 0.03 mm. Quadrilateral eight-node element is used for the workpiece
with an element size of 0.05.
Figure 1 shows the ¯nite element mesh for Ti–6Al–4V work material and CBN
tool used for simulation and Fig. 2 shows the ¯nite element simulation with ¯xed
support and displacement.
3. Results and Discussion

Due to complex deformation at the tool–work interface during the machining of Ti–
6Al–4V, using L16 orthogonal array-based ¯nite element analysis for the prediction
of machining process output variables such as cutting force and chip formation
mechanism has been discussed.
3.1. Cutting force analysis during the machining of Ti–6Al–4V using FEM
Cutting force analysis during the machining of Ti–6Al–4V has been carried out using
the results obtained from L16 orthogonal array-based ¯nite element analysis. Table 5
shows the FEM results using L16 orthogonal array for di®erent cutting speeds. From
Fig. 3 [main e®ects plot for the means for cutting force (N)], it is observed that as the
cutting speed increased from 100 m/s to 300 m/s, the cutting force reduced from 179 N
to 87.12 N. This clearly implies that as the cutting speed increases, there is less contact
between the tool and work which results in less frictional force and hence less cutting
force. Further increase in the depth of cut resulted in a decrease in the cutting force,
however, there was not much variation; but at 0.2-mm and 0.3-mm depths of cut, the
cutting force remained almost constant, i.e. 119.23 N. Similar observations are also
identi¯ed with the increase in rake angle, clearance angle and nose radius. Hence, the
minimum cutting force, stress and strain values at the tool–work interface during the
machining of Ti–6Al–4V can be obtained at cutting speed of 300 m/s, depth of cut of
0.30 mm, rake angle of 5 , clearance angle of 7 and nose radius of 0.020 mm (Fig. 4).
Table 5. FEM results using L16 orthogonal array.
Cutting speed Depth of cut Rake angle Clearance angle Nose radius Cutting
Trial no. (m/min) (A) (mm) (B) (deg) (C) (deg) (D) (mm) (E) force (N)
1 100 0.10 5 4 0.010 226.51

2 150 0.10 0 6 0.030 142.73
3 200 0.10 5 7 0.015 120.66
4 300 0.10 10 5 0.020 98.775
Fig. 3. Main e®ects plot for the means for cutting force (N).
Figures 5(a)–5(d) show the results obtained from L16 orthogonal array-based ¯nite
element analysis for the cutting force, stress and strain distribution contours at the
tool–work interface during the machining of Ti–6Al–4V under di®erent cutting
conditions.
Fig. 4. FEM results for the minimum cutting force, stress and strain values at the tool–work interface
during the machining of Ti–6Al–4V under the cutting speed of 300 m/s, depth of cut of 0.30 mm, rake
angle of 5 , clearance angle of 7 and nose radius of 0.020 mm.
(a)
(b)
Fig. 5. Cutting force, stress and strain distribution contours at the tool–workpiece interface during the
machining of Ti–6Al–4V under the following cases: (a) Cutting speed: 100 m/s, depth of cut: 0.10 mm, rake
angle: 5 , clearance angle: 4 and nose radius: 0.010 mm; (b) cutting speed: 150 m/s, depth of cut:
0.10 mm, rake angle: 0 , clearance angle: 6 and nose radius: 0.030 mm; (c) cutting speed: 200 m/s, depth of
cut: 0.10 mm, rake angle: 5 , clearance angle: 7 and nose radius: 0.015 mm; and (d) cutting speed: 300 m/s,
depth of cut: 0.10 mm, rake angle: 10 , clearance angle: 5 and nose radius: 0.020 mm.
(c)
(d)
Fig. 5. (Continued )
3.2. Chip formation analysis during the machining of Ti–6Al–4V using

FEM
Chip formation process using FEM analysis helps in identifying the machinability
characteristics of any metals and alloys since it certainly a®ects the machined surface
and cutting tool material. During the machining of Ti–6Al–4V, serrated-type saw-
toothed chips are formed due to adiabatic shearing and thermal deformation.26
Fig. 6. Chip formations during the machining of Ti–6Al–4V under di®erent cutting conditions.
In this research, ¯nite element analysis has been made to understand the chip
formation under di®erent cutting conditions, such as cutting speed, depth of cut,
clearance angle, rake angle and nose radius, based on the L16 orthogonal array. From
Fig. 6, it is observed that as the cutting speed increases, due to heat generated the
width of the adiabatic shear band decreases resulting in the increase of chip seg-
ments. At low cutting speed, saw-toothed chips tend to adhere onto the tool rake face
resulting in continuous chips and as the cutting speed increases, the chip tends to curl
in the form of saw-toothed serrated type and leaves the tool rake face discontinuously
due to adiabatic shear sensitivity and thermal distortion.27 Other than the cutting
speed, rake angle has an e®ect on the saw-toothed chip formation; this may be due to
the tendency of chip to slide on the tool rake face resulting in continuous chips at 5
and 0 . As the rake angle increased from 5 to 10 , continuous chips are broken into
discontinuous saw-toothed chips.
4. Conclusions
From the machining of Ti–6Al–4V using L16 orthogonal array-based ¯nite element
analysis for the prediction of machining process output variables such as cutting
force and chip formation mechanism, the following conclusions can be drawn:
. Finite element modeling is considered a technique used for solving complex engi-
neering problems and can be e®ectively used in metal cutting industries.
. From the main e®ects plot for the means for cutting force (N) obtained from DOE,
it was observed that as the cutting speed increased from 100 m/s to 300 m/s, the
cutting force reduced from 179 N to 87.12 N. This clearly implies that as the
cutting speed increases, there is less contact between the tool and work followed by
thermal softening which results in less frictional force and hence less cutting force.
Further increase in the depth of cut resulted in a decrease in cutting force, how-
ever, there was not much variation; but at 0.2-mm and 0.3-mm depths of cut, the
cutting force remained almost constant, i.e. 119.23 N.
. From the ¯nite element analysis, it was observed that as the cutting speed
increases, due to heat generated the width of the adiabatic shear band decreases
resulting in the increase of chip segments. At low cutting speed, saw-toothed chips
tend to adhere onto the tool rake face resulting in continuous chips and as the
cutting speed increases, the chip tends to curl in the form of saw-toothed serrated
type and leaves the tool rake face discontinuously due to adiabatic shear sensi-
tivity and thermal distortion.
. The developed L16 orthogonal array-based ¯nite element analysis can
e®ectively be used to predict and estimate the cutting force and chip formation
mechanism.
Acknowledgments
The authors would like to thank the Mechanical Engineering Department of
National Institute of Technology, Surathkal, India for providing the lab facilities for
carrying out the research work.
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L Orthogonal Array-Based Three-Dimensional Finite Element Modeling For Cutting Force and Chip Formation Analysis During Dry Machining of Ti - 6Al-4V

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Journal of Advanced Manufacturing Systems

Vol. 20, No. 1 (2021) 123–134

L16 Orthogonal Array-Based Three-Dimensional Finite

of major concern.5 Reference 6 suggested that Taylor's empirical equations do not

Table 1. Chemical composition of Ti–6Al–4V.24

wt.% 6.1 4 0.16 0.11 0.02 0.01 0.001 0.001 Bal.

Table 2. Mechanical properties of the titanium

Property Typical value

Hardness (Rockwell scale) 30

Table 3. Levels and factors.

1 100 0.10 5 4 0.010

Table 4. Control factor settings as per L16 orthogonal array.

1 100 0.10 5 4 0.010

10 200 0.15 10 6 0.010

Fig. 2. Finite element simulation with ¯xed support and displacement.

support and displacement.

3. Results and Discussion

Table 5. FEM results using L16 orthogonal array.

1 100 0.10 5 4 0.010 226.51

3.2. Chip formation analysis during the machining of Ti–6Al–4V using

operations at MAL-UBC, in Proc. CIRP 2000 Machining Workshop (2000).

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