Ultrasonically assisted turning of Ti-6Al-2Sn-4Zr-6Mo

Titanium alloys are widely used in the aerospace and offshore industries due to their high strength-to-weight ratio sustained at elevated temperatures, their fracture-resistance features and exceptionally good corrosion-resistance properties. However, poor thermal conductivity and high chemical affinity of these alloys to tool materials severely impair their machinability. As a result the machining processes of titanium alloys are typically characterized by low cutting feeds and speeds making production of components uneconomical.

Recently, a non-conventional hybrid machining technique, namely, ultrasonically assisted turning has been shown to significantly improve the machinability of intractable alloys with a concomitant improvement in material removal rates, thus improving machining economics. In the current work, a 3D finite element model of turning of Ti-6Al-2Sn-4Zr-6Mo is developed in the commercial software, MSC Marc/Mentat. A constitutive behaviour of the workpiece material under large deformations and elevated temperatures is adequately represented by a Johnson-Cook material model. For validation of the developed numerical model, experimental tests were carried out. The numerical and experimental results were found to be in good agreement.