Abstract
High speed milling of hard alloy steels utilized in dies and molds is a highly demanding operation. The finite element model was developed to investigate the high speed machining of alloy cast iron which is used in auto panel dies. The modified Johnson-cook constitutive model was used to model the complex dynamic material behavior, a damage evaluation law based on Cockroft and Latham model was used to simulate the ductile fracture of alloy cast iron. The crack initiation and propagation was simulated explicitly using an explicit FEM code. Simulation results showed that the chip morphology transited from continuous to saw-tooth chip with increasing cutting speed, cutting force decreased when increasing the cutting speed, which provide a useful understanding of chip formation process in high speed machining of alloy cast iron.
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