Optimization of the Cutting Process Parameters of Ti-6Al-4V Alloy using Hybrid Approach
Authors: Olodu DD, Ihenyen OI
The prediction of machining conditions for minimum cutting forces plays a very important role in machining stability, tool life and residual stresses. In this research, a series of simulations were run in order to evaluate the effect of cutting variables and optimize the cutting conditions to obtain lower cutting force for orthogonal cutting of titanium alloy (Ti-6Al-4V). A predictive Lagrangian-FEA model based on finite element method (FEM) which involved Johnson-Cook material model and fracture criterion was used to simulate chip shapes and cutting forces. The simulation runs plan was designed and carried out based on the central composite design (CCD). A mathematical linear model in terms of cutting speed and feed rate was developed for cutting force using FEA and optimized using response surface methodology (RSM). An optimum cutting force of 1165.04N was obtained at a cutting speed of 70m/min. and a feed rate of 0.21m/rev. The validity of the model shows that a coefficient of determination of 98% and adjusted coefficient of 97% were obtained. Finally, the simulation runs performed to verify the fitted model shows that its adequacy is within 95% prediction interval.
Affiliations: Department of Production Engineering, Faculty of Engineering, University of Benin, PMB 1154, Benin City, Nigeria.
Keywords: Central Composite Design, FEA Model, Hybrid Model, Response Surface Methodology, ANOVA
Published date: 2018/12/30