Simulation and experimental studies to verify the effect of cutting parameters on chip shrinkage coefficient and cutting forces in machining of A6061 aluminum alloy

Abstract

This article predicts the relationship between chip shrinkage coefficient and cutting parameters such as cutting speed and uncut chip thickness in a cutting process of A6061 aluminum alloy. To this end, shrinkage coefficient–based finite element method was first estimated using the Johnson–Cook (J-C) and Bao–Wierzbicki (B-W) material fracture models. After that, experimental measurements of the chip shrinkage coefficients were performed at the same cutting conditions to compare with simulation data and confirm the accuracy of material damage models. By a simultaneous evaluation of the effects of cutting parameters on the chip shrinkage coefficient, the B-W model was found to match well with the experiment. So that, the B-W model was then utilized to verify the effect of various cutting speeds and uncut chip thicknesses on the chip shrinkage coefficient and cutting force. Finally, using the least square method, the relationship between chip shrinkage coefficient and cutting force was obtained. The above-mentioned relationship is believed to be useful in determination of optimal cutting conditions in high-speed machining.