Finite Element Simulation of the Orthogonal Machining Process with Al 2024 T351 Aerospace Alloy

Abstract

Low density materials like Al 2024-T351 have found a wide range of applicability due to its capability of bearing high loads. To combat the need of extensive experimental trials to understand the orthogonal machining of Al 2024 T351, Finite element (FE) simulations have been employed. One of the most important parameters which determine the effectiveness of the FE code in the case of machining simulations is the flow stress model that is employed. However, there is a dearth of constitutive models in literature, capable of perfectly simulating the orthogonal machining of Al 2024 T351. The present work aims to assess and validate the performance of the JC constitutive equation in modelling the deformation behaviour of Al 2024-T351 alloy. Orthogonal machining experiments were conducted at nine different cutting conditions by varying cutting speed and feed. An FE model was constructed in Deform 2D and the flow stress data calculated from the JC model parameters, based on Oxley machining model was input into the FE code. The FE results for cutting force, chip thickness and temperature were compared with those of the experiments. The effective stress, strain and strain rate were analyzed for the various cutting conditions.