A Simulation of the Process of High Speed Milling of Titanium Alloy VT-1-0 in DEFORM-3D
Received: 23 June 2025 | Revised: 18 August 2025 | Accepted: 22 August 2025 | Online: 6 October 2025
Corresponding author: Sayagul Tussupova
Abstract
This study examined the High-Speed Milling (HSM) process of titanium alloy VT-1-0 using the Deform-3D simulation software. The simulation modeled the HSM operation and analyzed the distribution of temperature and strain in the cutting zone. The results indicated that deformation primarily occurred at the tool-workpiece interface and propagated more intensely into the sheared material at an angle of approximately 45°. Increasing the spindle speed of the end mill led to greater strain values in the cutting zone. Due to the low thermal conductivity of titanium, high temperatures-exceeding 1500 °C were localized at the tool-workpiece contact area. This concentration of heat, coupled with its slow dissipation throughout the workpiece, negatively affected the surface quality and tool life. Additionally, increasing both the feed rate and cutting speed resulted in higher temperatures and intensified friction at the interface.. The findings of this simulation provided valuable insights for optimizing the cutting parameters and better understanding the machinability of titanium under HSM conditions.
Keywords:
High-Speed Milling (HSM), titanium machinability, modeling, deformation, temperature, cutting parametersDownloads
References
H. A. Kishawy and A. Hosseini, Machining Difficult-to-Cut Materials: Basic Principles and Challenges. Cham, Switzerland: Springer International Publishing, 2019.
Q. He et al., "Enhancing Tool Performance in High-Speed End Milling of Ti-6Al-4V Alloy: The Role of AlCrN PVD Coatings and Resistance to Chipping Wear"' Journal of Manufacturing and Materials Processing, vol. 8, no. 2, Mar. 2024, Art. no. 68.
J. Matuszak, K. Zaleski, and A. Zyśko, "Investigation of the Impact of High-Speed Machining in the Milling Process of Titanium Alloy on Tool Wear, Surface Layer Properties, and Fatigue Life of the Machined Object," Materials, vol. 16, no. 15, July 2023, Art. no. 5361.
Z. J. Zhu, J. Sun, and L. X. Lu, "Research on the Influence of Tool Wear on Cutting Performance in High-Speed Milling of Difficult-to-Cut Materials," Key Engineering Materials, vol. 693, pp. 1129–1134, May 2016.
L. Yujiang and C. Tao, "Research on cutting performance in high-speed milling of TC11 titanium alloy using self-propelled rotary milling cutters," The International Journal of Advanced Manufacturing Technology, vol. 116, no. 7, pp. 2125–2135, July 2021.
G. Wang, X. Liu, T. Chen, and W. Gao, "An Experimental Study on Milling Titanium Alloy with a Revolving Cycloid Milling Cutter," Applied Sciences, vol. 10, no. 4, Feb. 2020, Art. no. 1423.
W. Ming, X. Huang, M. Ji, J. Xu, F. Zou, and M. Chen, "Analysis of cutting responses of Sialon ceramic tools in high-speed milling of FGH96 superalloys," Ceramics International, vol. 47, no. 1, pp. 149–156, Jan. 2021.
L. Janardhan, K. Chandrappa, and R. Suresh, "An Experimental Study on High-Speed Milling of Super Duplex Stainless Steel and to Investigate the Effect of Cutting Parameters on Surface Roughness," Journal of The Institution of Engineers (India): Series D, vol. 105, no. 1, pp. 127–132.
D. Maohua, J. Junhua, and J. Jianwei, "Robust Design Optimization Analysis of Experimental Results for High-Speed Milling of Alloy Cast Iron," China Mechanical Engineering, vol. 30, no. 5, 2019, Art. no. 554.
V. N. Trusov, D. L. Skuratov, O. I. Zakonov, and V. V. Shikin, "Calculation of Cutting Temperature at Milling of Purveyances from Hard-Processing Materials," Bulletin of the Samara State Aerospace University, vol. 27, no. 3, pp. 57–62, 2011.
A. N. Sellvanov and T. G. Nasad, “The Quality Mainentance of Processing Shafts From Titanium Alloys by High-Speed Milling and Turn-Milling Methods,” Bulletin of the Saratov State Technical University, pp. 55–61, 2010.
T. H. Le, V. B. Pham, and T. D. Hoang, "Surface Finish Comparison of Dry and Coolant Fluid High-Speed Milling of JIS SDK61 Mould Steel," Engineering, Technology & Applied Science Research, vol. 12, no. 1, pp. 8023–8028, Feb. 2022.
L. I. Vereina and M. M. Krasnov, Machine Operator’s Handbook: A Textbook for Initial Vocational Education. 2nd ed., Moscow, Russia: Moscow Publishing Center "Academy," 2008.
B. I. Cherpakov and L. I. Vereina, Technological Equipment of Machine-Building Production: A Textbook for Students of Secondary Vocational Education Institutions, 6th ed. Moscow, Russia: Moscow Publishing Center "Academy," 2015.
S. O. Tusupova and L. N. Makhmudov, "State of the Problem of Processing Hard-to-Machine Materials," Science and Technology of Kazakhstan, no. 3, pp. 71–83, 2023.
B. Deepanraj, N. Senthilkumar, G. Hariharan, T. Tamizharasan, and T. Tefera Bezabih, "Numerical Modelling, Simulation, and Analysis of the End-Milling Process Using DEFORM-3D with Experimental Validation," Advances in Materials Science and Engineering, vol. 2022, no. 1, 2022, Art. no. 5692298.
A. Mathivanan, G. Swaminathan, P. Sivaprakasam, R. Suthan, V. Jayaseelan, and M. Nagaraj, "DEFORM 3D Simulations and Taguchi Analysis in Dry Turning of 35CND16 Steel," Advances in Materials Science and Engineering, vol. 2022, no. 1, 2022, Art. no, 7765343.
S. V. Kozlov and E. O. Shirshov, "Increasing the Efficiency of High-Speed Milling Modes for Titanium Alloy Parts," in XXXV International Scientific and Practical Conference "Problems of Technical and Physical-Mathematical Sciences in Light of Modern Research, Novosibirsk, Russia, 2021.
J. G. R, "A Constitutive Model and Data for Metals Subjected to Large Strains, High Strain Rates and High Temperatures," in 7th International Symposium on Ballistics, The Hague, Netherlands, 1983.
P. Vishwakarma and A. Sharma, "3D Finite Element Analysis of milling process for non-ferrous metal using deform-3D," in 10th International Conference of Materials Processing and Characterization, Mathura, India, Feb. 2020.
S. Stebunov, A. Vlasov, and N. Biba, "Prediction of fracture in cold forging with modified Cockcroft-Latham criterion," in 17th International Conference on Metal Forming, Toyohashi, Japan, Sept. 2018.
I. Ullah, S. Zhang, and S. Waqar, "Numerical and experimental investigation on thermo-mechanically induced residual stress in high-speed milling of Ti-6Al-4V alloy," Journal of Manufacturing Processes, vol. 76, pp. 575–587, Apr. 2022.
S. Kumar Khare and G. Singh Phull, "Analysis and optimization of cutting parameters under high-speed machining of Ti-6Al-4V alloy," in International Conference on Materials, Processing & Characterization (13th ICMPC), Telangana, India, 2022.
Downloads
How to Cite
License
Copyright (c) 2025 Karibek Sherov, Sayagul Tussupova, Nadezhda Kuzminova, Lutfiddin Makhmudov, Bakhtiyor Mardonov, Saule Ainabekova, Gulnur Abdugaliyeva, Gulnara Kokayeva, Saule Mendalieva, Sayat Kardassinov
This work is licensed under a Creative Commons Attribution 4.0 International License.
Authors who publish with this journal agree to the following terms:
- Authors retain the copyright and grant the journal the right of first publication with the work simultaneously licensed under a Creative Commons Attribution License that allows others to share the work with an acknowledgement of the work's authorship and initial publication in this journal.
- Authors are able to enter into separate, additional contractual arrangements for the non-exclusive distribution of the journal's published version of the work (e.g., post it to an institutional repository or publish it in a book), with an acknowledgement of its initial publication in this journal.
- Authors are permitted and encouraged to post their work online (e.g., in institutional repositories or on their website) after its publication in ETASR with an acknowledgement of its initial publication in this journal.
