MPM simulations of high-speed and ultra high-speed machining of titanium alloy (Ti–6Al–4V) based on fracture energy approach

Based on material point method (MPM), two dimensional (2D) orthogonal chip model on titanium alloy is established. Unlike finite element method (FEM) with seriously distorted meshes during the simulation of large strains such as the formation of shear band, the MPM is especially suitable for the numerical simulation of large deformation and high strain rate of metal material at high temperature. The generalized interpolation material point (GIMP) contact algorithm, Johnson–Cook model and Hillerborg׳s fracture energy criterion are used to simulate the cutting process on Ti–6Al–4V alloy. The parameters option and simulation process are first discussed, then the corresponding chip force and temperature field etc. are analyzed and compared with experimental data available. A good agreement has been found between them. Finally, the evolution of the temperature and cutting force are studied, and the effects of cutting speed and cutting feed rate on the chip morphology and cutting force are also investigated. It was the first time to simulate the serrated and discontinuous chips with the MPM and obtain relatively satisfactory results. The transition from serrated to discontinuous chips has been well captured in this paper.