Finite element analysis (FEA) is a numerical technique in which product behavior under various loading conditions is predicted for ease of manufacturing. Due to its flexibility, its receiving research attention across domain discipline. This chapter aims to provide numerical investigation on chip formation in micro-end milling of Ti-6Al-4V alloy. It is widely used for medical applications. The chip formation process is simulated by a 3D model of flat end mill cutter with an edge radius of 5 μm. Tungsten carbide is used as a tool material. ABACUS-based FEA package is used to simulate the chip formation in micro-milling operation. Appropriate input parameters are chosen from the published literature and industrial standards. 3-D orthogonal machining model is developed under symmetric proposition and assumptions in order to reveal the chip formation mechanism. It is inferred that the developed finite element model clearly shows stress development in the cutting region at the initial stage is higher. It reduces further due to tool wear along the cutting zone.
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Finite Element Analysis (FEA) is capable ofresolving complex non-linear problems. The first simulation of the machining process was done in the 1980s, and it was performed in 2D for orthogonal cutting using plain strain models (Shrot et al., 2012). To perform a simulation of the machining process, the most commonly used software programs are ANSYS, ABAQUS, and DEFORM3D.FEA is a vital tool appropriate for solving nonlinear and linear problems in a static and dynamic environment. Many pieces of literaturehave dealt with diverse models and simulation for specific machining problems (Vaziri et al., 2010). Mesh area of workpiece have diverse geometry and boundary conditions for testing, but most of the models aim at investigating the effects of chip morphology and cutting parameters (Arrazola et al., 2010). Every model has the same types of elements whichare usually quadrilateral in nature, with thermo-mechanical properties (CPE4RT,CP4RT,etc). A 2Dstrain analysis can be done in ABAQUS for the orthogonal cutting process by using a quadrilateral with the thermo-mechanical assumption (Munoz-Sanchez et al., 2011).
In FEA, complexities like varying shapes and loading conditions lead to an approximate solution. Due to flexibility and diversity, much attention has been given to such complexities in the engineering domain (Thanongsak et al., 2013). FEA was originated as a way to perform stress analyses, and it was initially began as the addition of a matrix method for structural analysis. Currently, this method is utilized for analysis in solid mechanics, fluid flow, heat transfer, and many other fields of interest. Many civil engineers use FEA extensively for analysing beams, plates, folded plates, space frames, shells, and rock mechanics-related problems. Analysis of both static and dynamic problems can be done by using FEA. Many FEA packages are currently available, and a few packages are NASTRAN, ANSYS,ABACUS, STAAD-PRO, and NISA (Rosa et al., 2007).