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Finite Element Modeling for Prediction the Effect of Nose Radius on Cutting Forces for Titanium (Ti - 6Al - 4V) Alloy

This paper presents a study the effect of nose radius (R z -mm) on the cutting forces during the machining process in a face milling operation for titanium (Ti-6Al-4V) alloy. To improve the prediction of the effect of nose radius (R z -mm) on cutting force components so the cutting tests were performed with various nose radiuses (R z -mm) while the depth of cut (d-mm), feed rate (f-mm/tooth) and cutting speed (v c- m/ min) were remained constant. The main cutting force (F c ) and feed cutting force (F t ) were measured by using the ABAQUS/EXPLICIT software simulation through the development a two-dimensional orthogonal cutting process of finite-element modeling. The results led to the conclusion that the nose radius (R z -mm) has affected directly on the cutting force components. An increase in the nose radius (R z -mm) led to more convergence in terms of behavior between the main cutting force (F c ) and feed cutting force (F t ) and its direct effect on the quality and quantity of product.