3D FEM simulation of helical milling hole process for titanium alloy Ti-6Al-4V

Chunhui Ji, Yonghang Li, Xuda Qin, Qing Zhao, Dan Sun, Yan Jin

Research output: Contribution to journalArticlepeer-review

20 Citations (Scopus)
1101 Downloads (Pure)


As an emerging hole-machining methodology, helical milling process has become increasingly popular in aeromaterials manufacturing research, especially in areas of aircraft structural parts, dies, and molds manufacturing. Helical milling process is highly demanding due to its complex tool geometry and the progressive material failure on the workpiece. This paper outlines the development of a 3D finite element model for helical milling hole of titanium alloy Ti-6Al-4V using commercial FE code ABAQUS/Explicit. The proposed model simulates the helical milling hole process by taking into account the damage initiation and evolution in the workpiece material. A contact model at the interface between end-mill bit and workpiece has been established and the process parameters specified. Furthermore, a simulation procedure is proposed to simulate different cutting processes with the same failure parameters. With this finite element model, a series of FEAs for machined titanium alloy have been carried out and results compared with laboratory experimental data. The effects of machining parameters on helical milling have been elucidated, and the capability and advantage of FE simulation on helical milling process have been well presented.
Original languageEnglish
Pages (from-to)1733-1742
Number of pages10
JournalInternational Journal of Advanced Manufacturing Technology
Issue number9
Early online date27 May 2015
Publication statusPublished - Dec 2015


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