Investigating Machinability and Surface Integrity in Dry Machining Simulation of Titanium Alloy Made by Additive Manufacturing and Experimental Validation

The development of reliable numerical tools for predicting the integrity of machined surfaces is significant. This paper introduces a new customized FE model to predict the deformation during turning of electron beam fused (EBM) Ti6Al4V alloy under dry cutting. The needle microstructure and exotic nano-hardness types of materials are modeled and implemented using a user subroutine in the FE model. The developed FE model provides the possibility of predicting the microstructure (thickness of alpha lamella), the changes in nano-hardness caused by machining operations in dry conditions.