Ti6Al4V titanium alloy is widely used in aerospace,aviation and other industries due to its excellent me-chanical properties.In order to realize the anti-fatigue machining of Ti6Al4V titanium alloy,influence of surface topography on the fatigue behavior of Ti6Al4V is examined in terms of the stress concentration.The milling surface characters are gen-erated by a proposed 3D surface topography prediction model.Data obtained from the surface topography prediction model are integrated in two different stress concentration model of the Arola-Ramulu model and finite element model to calculate the stress concentration factor.The presented model is verified using milling experiments.The simulated and measured sur-face topographies show good agreement in their texture and profile.A qualitative analysis revealed that the stress concentra-tion factor of Ti6Al4V in peripheral milling is positively related to the feed per tooth and the radial cutting depth,and nega-tively related to the cutting speed.The stress concentration factor is most sensitive to the variation of the feed per tooth.
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