FEM-simulation of machining induced surface plastic deformation and microstructural texture evolution of Ti-6Al-4V alloy

When high speed machining polycrystalline metal, severe plastic deformation usually undergoes in the machined surface layer, accompanied by the microstructural variation of the crystallographic orientation. In the present paper, the machined surface plastic deformation and microstructural texture evolution during high speed machining of titanium alloy Ti-6Al-4V were investigated using finite element method (FEM) simulation. Firstly, a two dimensional FEM model was established, and was validated in terms of cutting forces and chip shape characteristics with experimental results of orthogonal machining. The plastic deformation on the machined surface was analyzed on the basis of finite element simulation. Results revealed that the plastic shear strain was much larger than the other strains in different directions. In addition, the variation of plastic shear strain and strain rate versus cutting time was obtained. When the feed rate was constant, the strain decreased and the maximum strain rate increased as cutting speed increased. Finally, the machined surface texture was simulated and analyzed using the Viscoplastic Self-consistent (VPSC) program based on the variation of plastic shear strain and strain rate, combined with polycrystalline plasticity theory. The machined surface texture evolution during machining was expressed by pole figures and orientation distribution function (ODF) diagrams. And the cylinder texture was identified from the pole figures. Four typical shear textures, including Y, C1, C2, and B fiber textures, were obtained from the ODF diagrams. Meanwhile, the orientation density of texture decreased with the increasing of cutting speed.