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<p>Metal additive manufacturing (AM) technologies are widely developed across diverse applications, yet they often face limitations in achieving a fine surface finish. Semi-finish machining of AM parts is an effective approach to enhance the functionality of final AM components. Despite the advantages of numerical methods, several critical challenges arise when machining simulations of AM materials are studied. This study develops a three-dimensional finite element model to simulate the dry machining of Electron Beam Melted (EBM) Ti6Al4V alloy, with the aim of predicting thermo-mechanical loads and microstructural responses. A user subroutine is implemented to provide a predictive modeling framework for evaluating machining parameters in additively manufactured Ti6Al4V, thereby bridging process conditions and microstructural evolution. The model is calibrated and validated against experimental data, showing agreement in cutting forces, temperature distribution, strain, alpha lamellae thickness, and nanohardness under varying machining conditions, including cutting speed, feed rate, and tool geometry (rake angle, edge radius, tool nose radius, and clearance angle). Utilizing this validated framework, the effects of tool geometry and cutting angles on machining performance are examined. Results indicate that increasing rake angle and certain tool geometries elevate machining forces due to enhanced tool–workpiece contact, while also significantly influencing nanohardness depth and alpha lamellae phase thickness. The tool nose radius is directly correlated with nanohardness depth, reflecting pronounced plastic deformation. Notably, a temperature rise from 393 to 680&#xa0;°C is observed when the tool-edge radius is increased from 10 to 30&#xa0;µm. Furthermore, higher tool angles lead to the doubling of both the depth of the hardened layer and the thickness of the α-phase.</p>

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Finite Element Analysis of Microstructural Evolution during Dry Machining of Additively Manufactured Ti6Al4V Alloy

  • 期刊论文

  • 发表日期：

    2026年1月5日

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  • Farshid Jafarian,
  • Mohammad Meghdad Fallah,
  • Mohsen Bahrami,
  • Mohammad Malekan

摘要

Metal additive manufacturing (AM) technologies are widely developed across diverse applications, yet they often face limitations in achieving a fine surface finish. Semi-finish machining of AM parts is an effective approach to enhance the functionality of final AM components. Despite the advantages of numerical methods, several critical challenges arise when machining simulations of AM materials are studied. This study develops a three-dimensional finite element model to simulate the dry machining of Electron Beam Melted (EBM) Ti6Al4V alloy, with the aim of predicting thermo-mechanical loads and microstructural responses. A user subroutine is implemented to provide a predictive modeling framework for evaluating machining parameters in additively manufactured Ti6Al4V, thereby bridging process conditions and microstructural evolution. The model is calibrated and validated against experimental data, showing agreement in cutting forces, temperature distribution, strain, alpha lamellae thickness, and nanohardness under varying machining conditions, including cutting speed, feed rate, and tool geometry (rake angle, edge radius, tool nose radius, and clearance angle). Utilizing this validated framework, the effects of tool geometry and cutting angles on machining performance are examined. Results indicate that increasing rake angle and certain tool geometries elevate machining forces due to enhanced tool–workpiece contact, while also significantly influencing nanohardness depth and alpha lamellae phase thickness. The tool nose radius is directly correlated with nanohardness depth, reflecting pronounced plastic deformation. Notably, a temperature rise from 393 to 680 °C is observed when the tool-edge radius is increased from 10 to 30 µm. Furthermore, higher tool angles lead to the doubling of both the depth of the hardened layer and the thickness of the α-phase.