FE Modeling and Experimental Analysis of Residual Stresses in Vibration Assisted Turning of Ti6Al4V

Titanium alloys are widely employed in aerospace, marine and biomedical industries due to their durability and ability to sustain elevated operating temperature. Vibration assisted turning (VAT) is found to be an effective alternative to machine hard materials and promises significant process improvements compared to conventional turning (CT). This paper presents experimental studies and finite element simulations in turning of Ti6Al4V alloy with uncoated carbide tools. The influence of VAT on residual stress is evaluated in both experiment and simulation. The residual stresses are evaluated experimentally along the direction of cutting and perpendicular to the direction of cutting using X-ray diffraction analysis. 3-D finite element model is developed to predict cutting forces, temperature, and machining-induced stress field and the residual stresses. It is observed that the nature of residual stresses is predominantly compressive in VAT compared to CT, due to the reduced the cutting forces, effective stresses, and temperature.