A finite element assessment of the workpiece plastic deformation in machining of Ti-6Al-4V

Severe plastic deformation is not desired in machining as it adversely affects surface integrity. In this study, the performance of finite element formulations on subsurface plastic deformation is studied. Finite element models of orthogonal milling of Ti6Al4V have been developed using Update Lagrangian with element deletion as well as continuous remeshing algorithms. The models are validated not only by the measured cutting forces, but quantitative measurements of the subsurface plastic deformation. The results showed that continuous remeshing strategy generate smooth milling forces and predicted the plastic deformation of the machined subsurface with higher accuracy compared to the element deletion method.