Finite element study on chip morphology evolution of Ti6Al4V in micro-milling

Chip is an important index to reflect the quality of machining, and its geometric characteristics such as chip sawtooth degree, sawtooth frequency and radius of curvature are greatly affected by cutting parameters. In order to study and predict the evolution of serrated chip in micro-milling of titanium alloy, finite element analysis software ABAQUS was used to establish the finite element model. Based on elasto-plastic constitutive model, fracture criterion and friction model, the influences of linear velocity and feed per tooth on chip morphology and cutting force were simulated. The relationship between serrated chip formation and cutting force fluctuation is revealed, so as to further explore the chip formation mechanism.