Publication

Abstract : In the past few years there is a rise in demand for sustainable micro turned titanium alloy components in the field of aeronautical andbiomedical industries. But the major issues in micro turning of Ti-6Al-4V are fluctuations in the cutting force due to saw-tooth chipformation, chip adhesion on the cutting tool due to chemical affinity and high temperature in the tool-chip interface zone due to lowthermal conductivity. So the experimental analysis of addressing these issues of titanium alloy are expensive. In view of this, in thepresent work, a finite element simulations are developed to understand the process mechanics and also to predict the cutting, thrust andfeed forces, tool-chip interface temperature and chip morphology during dry and in-situ cryogenic micro turning process. Finite elementsimulations are developed using updated lagrangian approach by taking into account of edge radius, liquid nitrogen cooling and workhardening effects. A cylindrical heat exchange window is used in the simulation for in-situ cryogenic cooling. Finite elementsimulations are calibrated for various shear friction factors and finally validated with the forces and chip morphology results measuredexperimentally. It is inferred that in-situ cryogenic micro turning results in favorable chip formation, less tool-chip interface temperatureand minimize the formation of saw-tooth chip which lead to increase the overall accuracy and precision of micro turned titanium alloyimplants. However there is an increase in cutting forces when compared with dry machining due to cryogenic cooling and size effects.