Effect of Varying Tool Parameters on Chip Formation and Reaction Force

Ti6Al4V and Inconel 718 are widely used materials in the manufacturing industry and have tremendous application in major fields such as aerospace, automotive, oil and gas and other key industries. The machining of such materials has always been considered challenging. In this paper, Abaqus simulation modelling software has been used to perform orthogonal cutting finite element analysis with variation in rake angle and cutting speed. The parameters are selected for the analysis such as Johnson–Cook constitutive model, failure parameters and meshing parameters to ensure and validate the computational analysis in comparison with actual orthogonal cutting of these materials. The results portray few trends in the variation of tool parameters such as rake angle and cutting speed. The increase in rake angle leads to the decrease in shear banding, increase in smooth chip flow, decrease in chip curl diameter and increase in stress, while the increase in cutting speed led to the increase in stress and increase in surface finish.