The Effects of Cutting Parameters on the Characteristics of Chip and Cutting Force in High-Speed Milling of A6061 Aluminum Alloy
Main Article Content
Abstract
This paper studied the effects of cutting parameters (cutting speed, cutting depth, feed-rate) on the characteristics of chip and cutting force in high-speed milling of A6061 aluminum alloy using FEM with ABAQUS/Explicit commercial software. First, a FE model was created based on the Bao-Wierzbicki (B-W) material fracture model, which was extended from the Morh-Coulomb criteria. The simulation model was verified by comparing the morphologies of simulated chip and that obtained by SEM. Then, the effects of cutting paramters on the chip morphology, chip shrinkage coefficient and cutting force were investigated. The simulation results showed that the chip morphology significantly depends on the cutting speed. The explicit formulae, which reflect the relationship between cutting parameters on chip chip shrinkage coefficient and cutting force, were finally proposed.
Keywords
chip chip shrinkage coefficient, Bao-Wierzbicki model, A6061 aluminum alloy, cutting force
Article Details
References
[1] X. Cui and J. Zhao, Cutting performance of coated carbide tools in high-speed face milling of AISI H13 hardened steel, Int. J. Adv. Manuf. Technol 71 (2014) 1811-1824.
[2] V. Kauppinen, High-Speed Milling a New Manufacturing Technology, 4th Int. DAAAM Conf. Ind. Eng. Innov. as Compet. Edge SME, no. April (2004) 131-134.
[3] P. Lezanski and M. C. Shaw, Tool face temperature in high speed milling, ASME J. Eng. Ind., vol. 112, no. June 1988 (1990) 132-5.
[4] Z. Wang and M. Rahman, High-Speed Machining, in Comprehensive Materials Processing, vol. 11. Elsevier, (1992) 637-643.
[5] C. Wang, Y. Xie, L. Zheng, Z. Qin, D. Tang, and Y. Song, Research on the Chip Formation Mechanism during the high-speed milling of hardened steel, Int. J. Mach. Tools Manuf. 79, (2014) 31-48.
[6] X. Cui, J. Zhao, C. Jia, and Y. Zhou, Surface roughness and chip formation in high-speed face milling AISI H13 steel, Int. J. Adv. Manuf. Technol., 61 (2012) 1-13.
[7] B. Ramamoorthy and L. Vijayaraghavan, Effect of High Speed Cutting Parameters on the Surface Characteristics of Superalloy Inconel, Engineering. III (2010).
[8] V. D. Calatoru, M. Balazinski, J. R. R. Mayer, H. Paris, and G. L'Espérance, Diffusion wear mechanism during high-speed machining of 7475- T7351 aluminum alloy with carbide end mills, Wear, 26 (2008) 1793-1800.
[9] S. Zhang and J. Li, Tool wear criterion, tool life, and surface roughness during high-speed end milling Ti- 6Al-4V alloy, J. Zhejiang Univ. Sci. A, 11 (2010) 587-595.
[10] T. Data, Fracture characteristics of three metals subjected to various strains, strain rates temperatures and pressures, Eng. Mech 21(1985).
[11] M. S. Swan, Incorpration of a general criterion into a stress based plasticity model through a time to failure by, Thesis Mech. Eng. Univ. Utah, USA. (2012).
[12] O. Article, On predicting chip morphology and phase transformation in hard machining, Int Adv Manuf Technol, (2006) 645-654.
[13] J. Shi and C. R. Liu, Flow stress property of a hardened steel at elevated temperatures with tempering e ect, Int. J. Mech. Sci. 46 (2004) 891- 906.
[14] 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.
[15] D. J. L. M.G.Cockcroft, Ductility and the Workability of Metals. J Inst Metals, (1968).
[16] E. Ceretti, M. Lucchi, and T. Altan, FEM simulation of orthogonal cutting serrated chip formation, Juornal Mater. Process. Technol., 95 (1999) 17-26.
[17] J. Lorentzon, N. Järvstråt, and B. L. Josefson, Journal of Materials Processing Technology Modelling chip formation of alloy 718, J. Mater. Process. Technol, 209 (2009) 4645-4653.
[18] A. Gilioli, A. Manes, M. Giglio, and T. Wierzbicki, Predicting ballistic impact failure of aluminium 6061-T6 with the rate-independent Bao-Wierzbicki fracture model, International Journal of Impact Engineering, 76. (2015) 207-220.
[19] 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. 35 (2012). 317-327.
[20] R. Stringfellow and C. Paetsch, Modeling Material Failure During Cab Car End Frame Impact, in 2009 Joint Rail Conference, (2009) 183-192.
[21] X. Teng and T. Wierzbicki, Effect of fracture criteria on high velocity perforation of thin beams., Int. J. Comput. Methods, 1 (2004) 171-200.
[22] H. Z. Li and J. Wang, A cutting forces model for milling Inconel 718 alloy based on a material constitutive law, Proc. Inst. Mech. Eng. Part C J. Mech. Eng. Sci. 227 (2013) 1761-1775.
[23] Y. Chen, H. Li, and J. Wang, Analytical modelling of cutting forces in near-orthogonal cutting of titanium alloy Ti6Al4V. Proc. Inst. Mech. Eng. Part C J. Mech. Eng. Sci. 229 (2015) 1122-1133.
[24] M. H. Ali, B. a. Khidhir, M. N. M. Ansari, and B. Mohamed, FEM to predict the effect of feed rate on surface roughness with cutting force during face milling of titanium alloy, HBRC J., 9 (2013) 263-269.
[25] X. Cui, B. Zhao, F. Jiao, and J. Zheng, Chip formation and its effects on cutting force, tool temperature, tool stress, and cutting edge wear in high- and ultra-high-speed milling, Int. J. Adv. Manuf. Technol, 83 (2016) 55-65.
[26] A. Davoudinejad, E. Chiappini, S. Tirelli, M. Annoni, and M. Strano, Finite Element Simulation and Validation of Chip Formation and Cutting Forces in Dry and Cryogenic Cutting of Ti-6Al-4V, Procedia Manuf. 1 (2015) 728-739.
[27] D. Xu, P. Feng, W. Li, and Y. Ma, An improved material constitutive model for simulation of high- speed cutting of 6061-T6 aluminum alloy with high accuracy, Int. J. Adv. Manuf. Technol, 79 (2015) 1043-1053.
[28] M. Bäker, Finite element simulation of high-speed cutting forces, J. Mater. Process. Technol. 176 (2006) 117-126.
[29] J. P. Davim, C. Maranhão, M. J. Jackson, G. Cabral, and J. Grácio, FEM analysis in high speed machining of aluminium alloy (A17075-0) using polycrystalline diamond (PCD) and cemented carbide (K10) cutting tools, Int. J. Adv. Manuf. Technol. 39 (2008) 1093- 1100.
[30] M. H. Ali, B. a. Khidhir, B. Mohamed, and a. a. Oshkour, Prediction of High Cutting Speed Parameters for Ti-6Al-4V by Using Finite Element Modeling, Int. J. Model. Optim, 2, (2012) 31-35.
[31] Y. Bai and T. Wierzbicki, "Application of extended Mohr-Coulomb criterion to ductile fracture, Int. J. Fract, 161 (2010) 1-20.
[32] Y. Li, T. Wierzbicki, M. A. Sutton, J. Yan, and X. Deng, Mixed mode stable tearing of thin sheet Al 6061-T6 specimens: Experimental measurements and finite element simulations using a modified Mohr- Coulomb fracture criterion, Int. J. Fract. 168 (2011) 53-71.
[33] A. M. Beese, M. Luo, Y. Li, Y. Bai. and T. Wierzbicki, Partially coupled anisotropic fracture model for aluminum sheets, Eng. Fract. Mech. 77 (2010) 1128-1152.
[34] Nguyen Doan Y, Quy hoach thuc nghiem. NXB Khoa hoc ky thuat, Ha Noi (2003).
[2] V. Kauppinen, High-Speed Milling a New Manufacturing Technology, 4th Int. DAAAM Conf. Ind. Eng. Innov. as Compet. Edge SME, no. April (2004) 131-134.
[3] P. Lezanski and M. C. Shaw, Tool face temperature in high speed milling, ASME J. Eng. Ind., vol. 112, no. June 1988 (1990) 132-5.
[4] Z. Wang and M. Rahman, High-Speed Machining, in Comprehensive Materials Processing, vol. 11. Elsevier, (1992) 637-643.
[5] C. Wang, Y. Xie, L. Zheng, Z. Qin, D. Tang, and Y. Song, Research on the Chip Formation Mechanism during the high-speed milling of hardened steel, Int. J. Mach. Tools Manuf. 79, (2014) 31-48.
[6] X. Cui, J. Zhao, C. Jia, and Y. Zhou, Surface roughness and chip formation in high-speed face milling AISI H13 steel, Int. J. Adv. Manuf. Technol., 61 (2012) 1-13.
[7] B. Ramamoorthy and L. Vijayaraghavan, Effect of High Speed Cutting Parameters on the Surface Characteristics of Superalloy Inconel, Engineering. III (2010).
[8] V. D. Calatoru, M. Balazinski, J. R. R. Mayer, H. Paris, and G. L'Espérance, Diffusion wear mechanism during high-speed machining of 7475- T7351 aluminum alloy with carbide end mills, Wear, 26 (2008) 1793-1800.
[9] S. Zhang and J. Li, Tool wear criterion, tool life, and surface roughness during high-speed end milling Ti- 6Al-4V alloy, J. Zhejiang Univ. Sci. A, 11 (2010) 587-595.
[10] T. Data, Fracture characteristics of three metals subjected to various strains, strain rates temperatures and pressures, Eng. Mech 21(1985).
[11] M. S. Swan, Incorpration of a general criterion into a stress based plasticity model through a time to failure by, Thesis Mech. Eng. Univ. Utah, USA. (2012).
[12] O. Article, On predicting chip morphology and phase transformation in hard machining, Int Adv Manuf Technol, (2006) 645-654.
[13] J. Shi and C. R. Liu, Flow stress property of a hardened steel at elevated temperatures with tempering e ect, Int. J. Mech. Sci. 46 (2004) 891- 906.
[14] 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.
[15] D. J. L. M.G.Cockcroft, Ductility and the Workability of Metals. J Inst Metals, (1968).
[16] E. Ceretti, M. Lucchi, and T. Altan, FEM simulation of orthogonal cutting serrated chip formation, Juornal Mater. Process. Technol., 95 (1999) 17-26.
[17] J. Lorentzon, N. Järvstråt, and B. L. Josefson, Journal of Materials Processing Technology Modelling chip formation of alloy 718, J. Mater. Process. Technol, 209 (2009) 4645-4653.
[18] A. Gilioli, A. Manes, M. Giglio, and T. Wierzbicki, Predicting ballistic impact failure of aluminium 6061-T6 with the rate-independent Bao-Wierzbicki fracture model, International Journal of Impact Engineering, 76. (2015) 207-220.
[19] 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. 35 (2012). 317-327.
[20] R. Stringfellow and C. Paetsch, Modeling Material Failure During Cab Car End Frame Impact, in 2009 Joint Rail Conference, (2009) 183-192.
[21] X. Teng and T. Wierzbicki, Effect of fracture criteria on high velocity perforation of thin beams., Int. J. Comput. Methods, 1 (2004) 171-200.
[22] H. Z. Li and J. Wang, A cutting forces model for milling Inconel 718 alloy based on a material constitutive law, Proc. Inst. Mech. Eng. Part C J. Mech. Eng. Sci. 227 (2013) 1761-1775.
[23] Y. Chen, H. Li, and J. Wang, Analytical modelling of cutting forces in near-orthogonal cutting of titanium alloy Ti6Al4V. Proc. Inst. Mech. Eng. Part C J. Mech. Eng. Sci. 229 (2015) 1122-1133.
[24] M. H. Ali, B. a. Khidhir, M. N. M. Ansari, and B. Mohamed, FEM to predict the effect of feed rate on surface roughness with cutting force during face milling of titanium alloy, HBRC J., 9 (2013) 263-269.
[25] X. Cui, B. Zhao, F. Jiao, and J. Zheng, Chip formation and its effects on cutting force, tool temperature, tool stress, and cutting edge wear in high- and ultra-high-speed milling, Int. J. Adv. Manuf. Technol, 83 (2016) 55-65.
[26] A. Davoudinejad, E. Chiappini, S. Tirelli, M. Annoni, and M. Strano, Finite Element Simulation and Validation of Chip Formation and Cutting Forces in Dry and Cryogenic Cutting of Ti-6Al-4V, Procedia Manuf. 1 (2015) 728-739.
[27] D. Xu, P. Feng, W. Li, and Y. Ma, An improved material constitutive model for simulation of high- speed cutting of 6061-T6 aluminum alloy with high accuracy, Int. J. Adv. Manuf. Technol, 79 (2015) 1043-1053.
[28] M. Bäker, Finite element simulation of high-speed cutting forces, J. Mater. Process. Technol. 176 (2006) 117-126.
[29] J. P. Davim, C. Maranhão, M. J. Jackson, G. Cabral, and J. Grácio, FEM analysis in high speed machining of aluminium alloy (A17075-0) using polycrystalline diamond (PCD) and cemented carbide (K10) cutting tools, Int. J. Adv. Manuf. Technol. 39 (2008) 1093- 1100.
[30] M. H. Ali, B. a. Khidhir, B. Mohamed, and a. a. Oshkour, Prediction of High Cutting Speed Parameters for Ti-6Al-4V by Using Finite Element Modeling, Int. J. Model. Optim, 2, (2012) 31-35.
[31] Y. Bai and T. Wierzbicki, "Application of extended Mohr-Coulomb criterion to ductile fracture, Int. J. Fract, 161 (2010) 1-20.
[32] Y. Li, T. Wierzbicki, M. A. Sutton, J. Yan, and X. Deng, Mixed mode stable tearing of thin sheet Al 6061-T6 specimens: Experimental measurements and finite element simulations using a modified Mohr- Coulomb fracture criterion, Int. J. Fract. 168 (2011) 53-71.
[33] A. M. Beese, M. Luo, Y. Li, Y. Bai. and T. Wierzbicki, Partially coupled anisotropic fracture model for aluminum sheets, Eng. Fract. Mech. 77 (2010) 1128-1152.
[34] Nguyen Doan Y, Quy hoach thuc nghiem. NXB Khoa hoc ky thuat, Ha Noi (2003).