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For decades many models of orthogonal cutting have been developed with limited practical application. In the scope of Industry 4.0, a need is felt to develop models of practical machining operations, like turning, milling, and drilling. This research work contributes for the development of reliable 3D models of practical machining operations by proposing a model of turning using a constitutive model considering the effects of the state of stress and strain-rate on the elasto-viscoplastic and damage behaviors of Ti-6Al-4V alloy. The accuracy of the 3D turning model was evaluated by comparing the predicted machining outcomes (forces, chip thickness, residual stresses, and thickness of strain-hardened layer) with those obtained experimentally. The model can predict quite well the cutting force but underestimate the feed force. The predicted residual stresses match reasonably well the experimental ones in both circumferential and axial direction, and the simulated thicknesses of strain hardened layer were close to the experimental ones. ANOVA permitted to investigate the influence of the cutting conditions on the thermomechanical phenomena and surface integrity. Suggestions to improve 3D models of practical machining operations are proposed.

3D modeling of turning of Ti-6Al-4V titanium alloy using a constitutive model considering the state of stress