Investigating the Impact of Declination Angle on the Side Milling Process of Additively Manufactured Ti6Al4V Using a 3D Milling Finite Element Model

Abstract

This study investigates the impact of declination angles (at 5, 10, and 15°) on the side milling process of additively manufactured Ti6Al4V. The finite element modelling (FEM) simulations are conducted using the Abaqus software and the Johnson–Cook (J-C) model. The main focus is on characterizing the relationship between the declination angles and the cutting forces. The findings demonstrate the significant effects of the declination angle, with noticeable variations observed in the milling forces. By employing the 3D milling finite element model of Abaqus, accurate analyses and predictions of the machining process dynamics are achieved. The insights gained from this research are valuable for optimizing machining parameters and enhancing efficiency, as well as for improving the surface quality of milled additively manufactured Ti6Al4V components.

Keywords

• milling
• additive manufacturing
• FEM
• Ti6Al4V