Investigation of Finite Element Modelling on Thin-Walled Machining of Ti6Al4V using DEFORM-3D

Ti6Al4V is one of material that difficult to be machined, and the machining process on thin-walled is also a challenge by the manufacturer. In order to avoid error in thin-walled machining, the FEM simulation using DEFORM-3D is conducted to acquire characteristic along the thin-wall. Dynamic deformation will be presented as stability of thin-wall, which is depicted in movement of the point tracking. As validation in this investigation, the experiment was conducted with 42-degree helical end-mill, which is connected to dynamometer that is obtained the cutting force value. The results showed that the FEM-simulation is failed to approach the experimental results. Some of the suspected reasons are the occurred unpredictable vibration, too small depth of cut.