Finite element simulation and experimental analysis of orthogonal cutting of an aluminium alloy using Polycrystalline Diamond tools

The current paper presents a Finite Element Model (FEM) simulation and experimental analysis of orthogonal cutting on aluminium alloy using Polycrystalline Diamond (PCD) tools. FEM machining simulations used a Lagrangian finite element-based machining model, AdvantedgeTM, applied to predict cutting forces, temperature distribution, plastic strain, von Mises and maximum shear stresses. The orthogonal cutting model was validated by comparing cutting forces obtained experimentally with a thermo-mechanical FEM analysis under orthogonal cutting conditions. Finally, FEM analysis prediction of the evolution of plastic strain, von Mises stress and maximum shear stresses during the machining of a commonly used aluminium alloy using PCD tools was conducted.

[1]  D. Umbrello,et al.  The influence of Johnson–Cook material constants on finite element simulation of machining of AISI 316L steel , 2007 .

[2]  Taylan Altan,et al.  Estimation of tool wear in orthogonal cutting using the finite element analysis , 2004 .

[3]  M. Cotterell,et al.  Minimal lubrication machining of aluminium alloys , 2002 .

[4]  M. Ortiz,et al.  Modelling and simulation of high-speed machining , 1995 .

[5]  Wit Grzesik,et al.  FINITE DIFFERENCE METHOD-BASED SIMULATION OF TEMPERATURE FIELDS FOR APPLICATION TO ORTHOGONAL CUTTING WITH COATED TOOLS , 2005 .

[6]  Guy Sutter,et al.  Chip geometries during high-speed machining for orthogonal cutting conditions , 2005 .

[7]  S. Engin Kilic,et al.  A comparison of orthogonal cutting data from experiments with three different finite element models , 2004 .

[8]  J. Monaghan,et al.  Modelling the orthogonal machining process using coated cemented carbide cutting tools , 2001 .

[9]  C. H. Shen,et al.  The importance of diamond coated tools for agile manufacturing and dry machining , 1996 .

[10]  E. Ezugwu,et al.  An overview of the machinability of aeroengine alloys , 2003 .

[11]  Hédi Hamdi,et al.  Numerical modelling of orthogonal cutting: influence of numerical parameters , 2005 .

[12]  Taylan Altan,et al.  EFFECTS OF FLOW STRESS AND FRICTION MODELS IN FINITE ELEMENT SIMULATION OF ORTHOGONAL CUTTING—A SENSITIVITY ANALYSIS , 2005 .

[13]  J. Paulo Davim,et al.  FEM analysis in high speed machining of aluminium alloy (Al7075-0) using polycrystalline diamond (PCD) and cemented carbide (K10) cutting tools , 2008 .

[14]  Tuğrul Özel,et al.  The influence of friction models on finite element simulations of machining , 2006 .

[15]  Troy D. Marusich,et al.  NUMERICAL SIMULATIONS OF DUCTILE MACHINING OF SILICON NITRIDE WITH A CUTTING TOOL OF DEFINED GEOMETRY , 2001 .