An Experimental Investigation of the High-Speed Milling of VT1–0 Titanium Alloy and Cutting Parameter Optimization Using Numerical Modeling

Abstract

This paper presents the results of an experimental study on high-speed milling of the VT1–0 titanium alloy. A solid carbide end mill, MC089, with a diameter of 16 mm, was used as the cutting tool. The results indicated that the influence of the cutting parameters on the machined surface roughness is complex. An increase in spindle speed has a positive effect on surface roughness, whereas an increase in feed rate and depth of cut has a negative effect. The optimal cutting parameters were determined as follows: spindle speed nsp=4200 rot/min, depth of cut t=1 mm, and feed rate S=4500 mm/min. A numerical modeling methodology was developed to determine the optimal cutting parameters for the same process. A three-dimensional model of the "tool–workpiece" system was developed using KOMPAS-3D and ANSYS Workbench, and the Johnson–Cook material failure model was selected. The contact interaction was defined, and a finite element model was developed. A numerical design of experiments was carried out using a rational planning method with variation of the main machining parameters, including depth of cut, feed rate, and spindle speed. As a result, temperature fields, contact forces, and plastic strain distributions were obtained. In addition, a mathematical model was developed to predict the workpiece temperature as a function of machining parameters. The minimization of the objective function enabled identifying the optimal cutting parameters that ensure minimal thermal impact: depth of cut t = 1 mm, feed rate S = 4500 mm/min, and spindle speed nsp = 4162 rot/min. Comparison with the experimental results showed a slight discrepancy in the optimal cutting values. The proposed methodology can be used to reduce the cost of conducting physical experiments and improve machining efficiency.