Modeling of Micro Turning Process with Finite Elements Method and Selection of Suitable Material Model

Developing technology in the manufacturing industry and the requirement of high precision parts reveals micro machining. It is possible to produce workpieces both at high speed and with high precision by means of micro-mechanical machining.The finite element method, a numerical modelling technique, provides a significant advantage in obtaining data (stress, strain and temperature) that are difficult to experimentally detect. The most important element in the numerical modeling of the micro machining is; the correctness of the material model used. In this study, micro turning process is modeled numerically in 2D conditions. Deform-2D commercial software was used in the modeling. In the study, cutting forces obtained by experimental and numerical modeling are compared using different material models. As workpiece material, Ti6Al4V alloy, which is widely used in the biomedical applications, has been selected. Constant cutting speed (100m / min.) and different feed rate values are used. At the end of the study, it was observed that the Johnson-Cook (J-C) material model recommended by Kay (2002) is more compatible with the experimental results. It has been determined that the difference between the numerical model and experimental results is between 5-15%.