Study On Finite Element Simulation And Experiment Of High Speed Cutting Superalloy

High speed cutting is advanced manufacturing technology, which has applied widely in many industrial fields because of its series of advantages. Serrated chip is often generated during high speed cutting metal materials,the formation of the serrated chip almost affects every aspect of cutting process,such as cutting force, cutting temperature, cutting tool wear and quality of machined surface etc.Therefore, it is very necessary to study the relationship between formation of the serrated chip and machining parameters during the high speed cutting process.Chip formation and cutting force are the important contents which are used to study cutting mechanism,in this paper,finite element simulation and experimental methods are used to study the chip formation and cutting force during high speed cutting superalloy,it helps people to deepen understanding of the mechanism of high speed cutting.In this paper,large general-purpose commercial finite element software ABAQUS was used to establish the finite element model using the modeling method of no separation line, isotropic hardening material constitutive model based on temperature was used,in order to achieve the separation of the chip and the workpiece,shear damage criteria which belong to physical separation was used, the process of chip formation and cutting force during high speed cutting superalloy GH4169was simulated.,by changing the tool rake angle,cutting speed and cutting depth,the influences on the chip morphology and cutting force were studied,the simulation results were verified by experiment.Through comparative analysis of the simulation and experiment results,it is found that the serrated chip sawtooth degree increase with the decrease of rake angle,increase of cutting and cutting depth,cutting force decrease with the increase of rake angle and cutting speed and decrease of cutting depth,they are agreed very well,and the correctness of the finite element model is verified.By changing the coefficient of friction,the influences on the cutting force and normal stress at the bottom of the chip which contacted with the tool were studied, the simulated results show that cutting force and normal stress at the bottom of the chip which contacted with the tool increase with the increase of coefficient of friction.By changing the tool rake angle,the influence on the contact length between chip and tool was researched, study shows that the contact length between chip and tool is greater when the rake angle is smaller. Mises stress in the cutting process was also analyzed. By changing the tool rake angle,the influences on equivalent plastic strain and strain rate in the adiabatic shear band of serrated chip were researched, study show that the equivalent plastic strain and strain rate in the adiabatic shear band of serrated chip are greater when the rake angle is smaller.