3D finite element modelling of surface modification in dry and cryogenic machining of EBM Ti6Al4V alloy

The development of reliable numerical tools for predicting the machined surface integrity has become of primary importance nowadays. This paper introduces a novel customized FE model to predict microstructural changes generated during turning of the Electron Beam Melted (EBM) Ti6Al4V alloy under dry cutting and cryogenic cooling. The material peculiar fine acicular microstructure and the nano-hardness variation are modelled and implemented into a FE model by means of a User Subroutine. The developed FE model permits to predict the microstructure (alpha lamellae thickness), the plastic deformation (alpha lamellae deformation) and nano-hardness variations induced by machining operation under dry and cryogenic conditions.