Simulation And Experiment Analysis Of High Speed Cutting For Aluminum Silicon Alloy ADC12

The engine cylinder block, cylinder head manufactured of aluminum silicon alloy ADC 12 has the advantages of light weight, less fuel consumption, good thermal conductivity, anti-magnetic, resistant decorative and machinability etc. Because of the lack of high speed cutting simulation and technology research of ADC 12 alloy, the cutting parameters are not optimized, the machine tool utilization rate is low, and the spindle speed is low, and so on. In this paper, for an automobile engine cylinder block and cylinder head material mechanics performance study is less, cutting parameters and the way of clamps suboptimal problems are analyzed, which provides theoretical and experimental basis for cylinder block, cylinder head machining. The main research contents are as follows:In view of the aluminum silicon alloy ADC 12, static tensile, compression and dynamic tension and compression experiments are conducted. Then stress and strain curves of the material at different temperatures and different strain rates are draw. Through comprehensive analysis of the curves, the material elastic plastic constitutive model--Johnson cook constitutive model parameters are fit out. We conduct a quasi-static and uniaxial compressive test simulation by the alloy materials in the finite element software. It is concluded that the relationship between stress and strain and the experimental values is basic coincidence. And the effectiveness of the constitutive model is verified.Based on the finite element software ABAQUS the two-dimensional orthogonal cutting model is established. In the model, we chose the updated Lagrange method, thermo mechanical coupled finite element model, the Johnson cook constitutive relation model fitted out in front and reasonable friction model, finite element modeling method. And then, cutting force, stress and strain, cutting temperature and cutting chip shape of the material in high-speed cutting conditions is analyzed with numerical simulation; the influence of cutting parameters on them are discussed. Accordingly, we can choose the optimal cutting parameters.Through the experiment of high speed milling, cutting force on the finite element simulation results and experiments were carried out to verify the chip shape. When the cutting speed is less than 30m/s, the increase of cutting force with the cutting speed increases, when the cutting speed is greater than 30m/s, the increase of cutting force with the cutting speed decreases; the chip shape has been banded during the whole time. We can draw the conclusion that the finite element simulation results agree well with experimental results.The gasoline engine cylinder block and cylinder head through the milling based on the way test fixture. We conduct tests to mill the cylinder block, cylinder head by different loading clamp mode (different clamping point and different clamping force) for clamping for the top surface of cylinder block and the of the bottom surface of cylinder head milling, with a dial indicator measuring the flatness of the surfaces, through comparative analysis. It is concluded that for the cylinder body and cylinder cover of the optimal method.