Research on Conventional and High-Speed Machining Cutting Force of 7075-T6 Aluminum Alloy Based on Finite Element Modeling and Simulation

Abstract

In current industrial practice, the finite element modeling of the metal cutting process is essential. In this paper, finite element analysis of conventional and high-speed cutting of 7075-T6 aluminum alloy is carried out. A finite element model of the 7075-T6 aluminum alloy was developed using the Johnson Cook instant on equation to investigate the milling behavior of the alloy under conventional and high-speed conditions. The cutting forces in the X-direction, Y-direction, and Z-direction were predicted analytically for five groups of different Johnson Cook models with different material constants, and the predicted results were compared with the experimentally determined cutting forces to investigate the influence of the Johnson Cook constitutive model parameters on the simulation of the cutting forces of the 7075-T6 aluminum alloy. The results showed that the constitutive model parameters are inconsistent for conventional and higher speed cutting conditions. Under conventional cutting conditions, the JC4 model predicts the material factor cutting forces in good agreement with the experimental results, while under high-speed cutting conditions, the JC5 model predicts the material factor cutting forces in good agreement with the experimental results, but that the finite element model has good applicability in predicting machining performance. Only the experimental data obtained by covering the real strain, strain rate and temperature range to determine the material constant of the Johnson Cook constitutive equation can accurately predict the cutting force in all directions.