Abstract The numerical analysis, based on the finite element modeling (FEM), presents nowadays an efficient computational tool. It allows a better understanding of several thermo-mechanical phenomena involved during the machining process. However, its reliability heavily depends on the accurate definition of the numerical model. In this regard, a FE analysis focused on the 2D modeling of the Ti6Al4V dry orthogonal machining was carried out in this study. The relevance of different numerical meshing approaches and finite elements topologies was studied. The effect of the friction coefficient on the numerical chip morphology, its geometry, the cutting and the feed forces was investigated. The adequacy of several compared adaptive meshing approaches, in terms of the modeling of severe contact conditions taking place around the cutting-edge radius, was underlined in the current study. However, numerical serrated chips, closer to the experimental ones, were only predicted when the pure Lagrangian formulation was adopted and a proper determination of the failure energy was carried out. The definition of different mesh topologies highlighted the efficiency of the 4-node quadrangular mesh, with a suitable edge length, in increasing the agreement with the experimental data, while reducing the computing times.

中文翻译：

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数值参数对 Ti6Al4V 加工建模可靠性影响的二维有限元分析

摘要 基于有限元建模（FEM）的数值分析是当今一种有效的计算工具。它可以更好地了解加工过程中涉及的几种热机械现象。然而，其可靠性在很大程度上取决于数值模型的准确定义。在这方面，本研究对 Ti6Al4V 干式正交加工的二维建模进行了有限元分析。研究了不同数值网格划分方法和有限元拓扑的相关性。研究了摩擦系数对数值切屑形态、几何形状、切削和进给力的影响。几种比较的自适应网格划分方法的充分性，在对切削刃半径周围发生的严重接触条件进行建模方面，在当前的研究中被强调。然而，只有在采用纯拉格朗日公式并正确确定失效能量时，才可以预测更接近实验结果的数值锯齿状切屑。不同网格拓扑的定义突出了具有合适边长的 4 节点四边形网格在增加与实验数据的一致性，同时减少计算时间方面的效率。