This paper presents the findings from numerical modeling of the turning process of titanium alloys with preheating of the workpiece. This modelling was conducted using the DEFORM-2D software environment, which is based on the finite element method (FEM). The objective of this study is to investigate the influence of workpiece temperature on cutting force and to determine the optimal heating parameters for machining materials that are challenging to process.
The modelling was performed for the Ti-6Al-4V alloy at temperatures ranging from 25 °C to 700 °C. The results obtained demonstrate that an increase in the workpiece temperature results in a substantial reduction in cutting force, exceeding 60%, which is attributable to the thermal softening effect of the material. The most substantial decrease in intensity is observed within the temperature range of 400–600 °C, where phase transformations from α to β occur, diffusion slip is initiated, and dynamic recrystallization takes place.
The employment of DEFORM facilitated a comprehensive investigation into the stress-strain state within the cutting zone, the temperature distribution, and the contact conditions between the tool and the workpiece. The simulation results confirm the effectiveness of preheating for improving the machinability of titanium alloys. The optimal heating temperature, approximately 550°C, ensures minimal cutting forces while maintaining process stability.
The findings thus obtained can be used to optimise the technological parameters of turning hard-to-cut materials under industrial conditions.
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