The Effect of Rake Angle and Cutting Edge Radius on the Orthogonal Cutting Process of Ti6Al4V Alloy

This paper investigates the effect of rake angle, α, cutting edge radius, r, and feed rate, f, on the cutting force and cutting zone temperature during orthogonal dry cutting of Ti6Al4V. A numerical model representative of the 2D orthogonal cutting process is developed using ABAQUS/Explicit software. Johnson-Cook, (JC) constitutive material model is used to describe material plasticity. JC damage model and energy-based fracture criterion are used to describe damage initiation and evolution. Using Minitab-19 software, Taguchi L9 orthogonal array (3 × 3) is implemented to plan simulation trails. Assuming a constant cutting speed of 500 mm/min, three levels for each factor are considered α (-5°, 0°, 5°), r (0.02, 0.04, 0.06 mm) and f (0.1, 0.2, 0.3 mm). The cutting force and cutting zone temperature are analyzed using ANOVA. Based on a 90% Confidence Interval (90% CI), the results show that only feed rate significantly affects the cutting force. However, rake angle, cutting edge radius, and feed rate do not substantially affect cutting zone temperature.