Abstract
Aluminium alloys are highly demanded in automobile, aerospace, and different manufacturing sectors due to their low density and high corrosion resistance. However, machining of these alloys creates problems due to their sticky characteristics with the cutting tool. The effect of cutting speed and nose radius on machining of Al-6061 alloy on forces and chip morphology using Finite Element Method (FEM) DEFORM-3D has studied. The effect of stress and temperature has investigated for the aluminum alloy. It is found that with the increase of cutting speed there is a reduction in forces, whereas the increase in forces with the increase in nose radius. The simulation results are validated using an experimental trial with the same cutting condition, and positive coherence between them is obtained.
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