Exploring the Impact of Machining Forces on Ball End Milling of Ti–6Al–4V Alloy through Single-Curve Simulation

In pursuit of unlocking the full potential of Ti–6Al–4V titanium alloy known for its exceptional strength-to-weight ratio, corrosion resistance, and stability at elevated temperatures, this study addresses the challenges in machining the alloy. Notably, its inherent hardness and reactivity with cutting tools present obstacles that impede the attainment of desired shapes and surface finish. This paper introduces a successful simulation of the cutting process of Ti–6Al–4V titanium alloy for a single curved sculptured surface using a ball nose end mill. The simulation is validated through experimental data, offering a practical approach to overcoming the alloy’s poor machinability and to allow forecasting the optimization of input machining parameters thereby promising superior machining outcomes. Results of this analysis show that the maximum cutting force for spindle speeds of 150 m/min is 749.72 N at a feed rate of 0.25 mm/tooth while for spindle speed of 180 m/min is 807.55 N at a feed rate of 0.3 mm/tooth and for 200 m/min is 834.58 N at a feed rate of 0.3 mm/tooth. Notably, this research contributes to advancing the understanding of Ti–6Al–4V machining, providing insights that have the potential to improve approaches within the industry involved in manufacturing of bio-implants such as hip joint, knee joint, etc.