Abstract
Because of the massive work and high cost of milling experiments, finite element analysis technology (FEA) was used to analyze the milling process of ADC12 aluminum alloy. An improved Johnson–Cook (J–C) constitutive equation was fitted by a series of dynamic impact tests in different strain rates and temperatures. It found that the flow stress gradually increases as the strain rate rises, but it decreases as the test temperature rises. Compared with the J–C constitutive model, the predicted flow stress by the improved J–C constitutive model was closer to the experimental results when the strain rate was larger than 8000 s−1 and the temperature was higher than 300 °C. A two-dimensional cycloidal cutting simulation model was constructed based on the two J–C constitutive equations which was validated by milling experiments at different cutting speeds. The simulation results based on the improved J–C constitutive equation were closer to the experimental results and showed the cutting force first increased and then decreased, with cutting speed increasing, reaching a maximum at 600 m/min.
Highlights
The ADC12 aluminum alloy has been widely used in engine cylinder bodies and heads with its low density, good casting performance, wear resistance, and small thermal expansion coefficient in recent years [1]
This paper fitted two J–C constitutive models based on the true stress–strain curve in different strain rates and temperatures of ADC12 alloy
By comparing the simulated cutting force and experimental cutting force, the cycloidal cutting finite element model could be validated
Summary
The ADC12 aluminum alloy has been widely used in engine cylinder bodies and heads with its low density, good casting performance, wear resistance, and small thermal expansion coefficient in recent years [1]. Many researchers have proposed the theoretical temperature field analytical model [9,10], finite element analysis model, and experimental verification [11,12,13,14,15] to analyze the temperature distribution of the high-speed cutting process. It found that the cutting force, which periodically changes during milling process, will produce higher temperatures at the tool–chip interface, further affecting tool wear and machining surface quality. Studying the variation of cutting force is helpful to analyze the tool wear behavior during high-speed milling of ADC12 alloy
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