Modelling of Micro-Machining of Ti-6Al-4V: Strain Gradient Interpretation

Advances in computer methods over the last two decades have accelerated research in engineering sectors because of high computing power. Micro-machining is a manufacturing domain that is widely utilized for producing miniature components where predictability is a concern. The current work emphasized developing and executing a user-defined constitutive flow and friction models to simulate the physical phenomenon of chip morphology, residual stresses, and cutting forces during orthogonal machining at the micro-scale. The proposed model integrates strain gradient and dynamic recrystallization effect using a user hardening subroutine written in Fortran for machining of Ti-6Al-4V in micron scale. Furthermore, a user defined friction subroutine was implemented at the tool-chip interaction. A comparison is made between the modelling results and experiments in terms of specific cutting energy (SCE) and residual stresses.