Determining the Optimal Parameters of Chip Shrinkage Coefficient and Cutting Force in High-Speed Machining for Aluminum Alloy A6061

Abstract:

Nowadays, increasing the productivity and the quality of machining become major challenges of the metal cutting process. Due to the complexity of the chip formation process, in particular, at high cutting speeds, finite element model (FEM) has been frequently used as an alternative solution. Chip shrinkage coefficient and cutting force are the two basic parameters of the cutting process, which determines the productivity and quality of the workpiece. This study uses a Grey correlation relationship to analyze and select the common set of parameters for cutting force and chip shrinkage coefficient of the chip. Simulation of the A6061 aluminum alloy high-speed milling is done by Bao-Wierzbicki's (B-W) model. The optimal parameters are determined cutting depth 1 mm, clearance angle 6^o and rake angle 10^o. This parameter set adjusts the cut parameters so that the cutting process achieves the highest machining efficiency.

• Periodical: Applied Mechanics and Materials (Volume 889)
• Pages: 123-130
• DOI: https://doi.org/10.4028/www.scientific.net/AMM.889.123
• Online since: March 2019
• Authors: Duc Thanh Pham, Nguyen Duc Toan, Thi Huong Doan, Thị Hoa Phạm
• Keywords: Bao-Wierzbicki Model, Chip Shrinkage Coefficient, Cutting Force, High-Speed Milling

References

[1] T. Data, Facture characteristics of three matals subjected to various strains, strain rates, temperatures and pressures, Eng. Mech., (1985)vol. 21, no. I.

[2] Y. Tan, Y. L. Chi, Y. Y. Huang, and T. Q. Yao, Finite Element Simulation of Extremely High Speed Machining of Ti6Al4V Alloy, Appl. Mech. Mater., vol. 141, (2011) 293–297. N.

DOI: 10.4028/www.scientific.net/amm.141.293

[3] G. Chen, C. Ren, X. Yang, X. Jin, and T. Guo, Finite element simulation of high-speed machining of titanium alloy (Ti-6Al-4V) based on ductile failure model, Int. J. Adv. Manuf. Technol. vol. 56, no. 9–12, (2011) 1027–1038.

DOI: 10.1007/s00170-011-3233-6

[4] C. Duan and L. Zhang, A reliable method for predicting serrated chip formation in high-speed cutting: Analysis and experimental verification, Int. J. Adv. Manuf. Technol., vol. 64, no. 9–12,(2013) 1587–1597.

DOI: 10.1007/s00170-012-4125-0

[5] O. Article, On predicting chip morphology and phase transformation in hard machining, Int Adv Manuf Technol, (2006) 645–654.

DOI: 10.1007/s00170-004-2242-0

[6] M. L. Wilkins, R. D. Streit, and J. E. Reaugh, Cumulative-Strain-Damage model of ductile fracture: Simulation and prediction of engineering fracture tests,Lawrence Livermore Natl. Lab.(1980)1–68.

DOI: 10.2172/6628920

[7] J. Lorentzon, N. Järvstråt, and B. L. Josefson, Journal of Materials Processing Technology Modelling chip formation of alloy 718, J. Mater. Process. Technol. vol. 209. (2009) 4645–4653.

DOI: 10.1016/j.jmatprotec.2008.11.029

[8] Y. Bao and T. Wierzbicki, On fracture locus in the equivalent strain and stress triaxiality space, Int. J. Mech. Sci. vol. 46, no. 1, (2004) 81–98.

DOI: 10.1016/j.ijmecsci.2004.02.006

[9] M. Giglio, A. Manes, and F. Viganò, Numerical simulation of the slant fracture of a helicopter's rotor hub with ductile damage failure criteria, Fatigue Fract. Eng. Mater. Struct. vol. 35, no. 4, (2012) 317–327.

DOI: 10.1111/j.1460-2695.2011.01622.x

[10] J. Liu, Y. Bai, and C. Xu, Evaluation of Ductile Fracture Models in Finite Element Simulation of Metal Cutting Processes, J. Manuf. Sci. Eng. vol. 136, no. February, (2013) 11010.

DOI: 10.1115/1.4025625

[11] P. Thi-Hoa, M. Thi-Bich, T. Van-Canh, B. Tien-Long, and N. Duc-Toan, A study on the cutting force and chip shrinkage coefficient in high-speed milling of A6061 aluminum alloy, Int. J. Adv. Manuf. Technol., no. 1, (2017) 1–12.

DOI: 10.1007/s00170-017-1063-x

[12] Banh Tien Long, Tran The Luc and Tran Sy Tuy. Metal Cutting Principles, 2nd Ed, Scienceand Technics Publishing House, (2013) (InVietnamese).