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FEM modelling of residual stresses of Ti-6Al-4V during micro-turning considering the scale effect

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Abstract

Numerical solutions based on the finite element technique is widely used over the last decade to develop a realistic model. FEM techniques are sufficiently capable to capture the underlying physics of complex nonlinear problems such as machining. Micro-turning is one such domain of manufacturing process in which material removes at micron range and extensively used in the fabrication of miniature parts such as electronic components, semiconductors, micro-tools. Ti-6Al-4V is widely used material due to its high specific strength and high corrosion resistance. The present work proposes a three-dimensional finite element study based on coupled thermo-mechanical transient analysis of micro-turning process to predict the surface and sub-surface residual stress of Ti-6Al-4V. The strain gradient factor has been coupled with Johnson-Cook flow model to capture the scale effect. Johnson-Cook damage criteria is used to capture the material separation. At low feed, radial and axial residual stresses altered the nature compressive to tensile at a depth 12 μm due to rubbing and ploughing, led to heat generation. Compressive residual stress increases with feed rate because of high strain rate and moreover, the circumferential residual stress (~ 1000 MPa) is found to be much higher than radial and axial. At low feed 3 μm/rev, maximum axial residual stress found at a depth 4 μm from machined surface due to accumulation of dislocation density owing to size effect. The predicted residual stress is validated with Nano-indentation technique and found to be in good agreement. All material properties of Ti-6Al-4V were measured to calculate the residual stress.

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Acknowledgements

The authors express their sincere gratitude to the Department of Science and Technology, Govt. of India for the research facilities under the FIST scheme (SR/FST/ETI 388/2015). The authors also thank Mr Rahul Yadav, Research Scholar, Department of Mechanical Engineering, Indian Institute of Technology Kharagpur, and Dr Jiju V Elias, Asst. Professor, Saingits College of Engineering, for all the support to complete this research.

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  1. Advanced Manufacturing Centre, National Institute of Technology Calicut, Kerala, 673601, India

    DEBENDRA KUMAR KHANDAI, JOSE MATHEW & BASIL KURIACHEN

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  1. DEBENDRA KUMAR KHANDAI
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  2. JOSE MATHEW
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Correspondence to BASIL KURIACHEN.

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KHANDAI, D.K., MATHEW, J. & KURIACHEN, B. FEM modelling of residual stresses of Ti-6Al-4V during micro-turning considering the scale effect. Sādhanā 47, 107 (2022). https://doi.org/10.1007/s12046-022-01865-8

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