Abstract: With the extensive application of titanium alloy,the machinability and the machined surface for Ti-6Al-4V has obtained widely attention,but the simulation of its machining process is not yet mature.Therefore,the cutting force,the cutting temperature,and the residual stress distribution at different depths from the machined surface were simulated by finite element method of Deform software during the turning process of titanium alloy Ti-6Al-4V under dry cutting,conventional coolant and high pressure coolant.Meanwhile the cutting force and the cutting temperature of the inserts were measured during the turning process for comparing with the simulation results.The simulation results showed that the high-pressure coolant can improve the cooling effect of the cutting process.With the increase of the pressure of coolant,the cutting force and the cutting temperature both increased decreased.The residual stress (d₂=0) is compressive stress under dry condition.With the coolant pressure increasing, the residual stress of the machined surface changed from the residual tensile stress to the residual compressive stress.The residual compressive stress is maximum under the coolant pressure of 200 bar.The value of residual stress increased with the measuring depth increasing.The maximum value of the residual compressive stress was observed at the same depth to the machined surface under all cutting condition.Compared with the experimental results,the reliability of the finite simulation is high,so that it is helpful to optimize the manufacturing parameters and provide the theoretical basis for the machining process of Ti-6Al-4V.

Key words: Ti-6Al-4V, finite element simulation, high pressure coolant, machining