The Finite Element Simulation Of High-speed Cutting Difficult-to-machine Materials

Nickel-based superalloys and titanium alloys are widely used by virtue of its goodphysical and mechanical properties, but they are typically difficult-to-machine materials.High-speed cutting technology has many advantages and possible ways to solve this problem,so high-speed machining performance of these materials is of great significance. In the cuttingfield, using the finite element software to simulate the cutting process is an effective andfeasible method.In this paper, the five key technologies of high-speed cutting difficult materials finiteelement simulation, such as the material model, adaptive mesh technology, chip separationcriterion, friction model and tool wear model are studied. And it describes the commercialfinite element software DEFORM-3D and AdvantEdge FEM turning simulation process; theapplication DEFORM-3D software on the nickel-base superalloy Incone1718finite elementsimulation of three-dimensional high-speed turning, the temperature field, the chip formationprocess and the stress field, developed a cutting force factors and four levels orthogonalexperiment to study the impact of cutting the amount of cutting force, and got a better fit ofthe empirical formula of the three cutting force; application AdvantEdge FEM softwaretitanium alloy Ti-6Al-4V, TI-5Al-2.5Sn ELI and Ti-10V-2Fe-3Al a finite element simulationof three-dimensional high-speed turning, the development of the six factors and five levels oforthogonal experimental program, the desired tool-chip contact temperature, the toolmaximum temperature, the main cutting force, the depth of cut resistance, feed force andcutting together a total of six indicators, six factors at different levels to study the impact ofvarious indicators, has been the best solution under the primary and secondary order of sixfactors for each indicator and indicators, and get a better goodness of fit three titanium alloycutting temperature and cutting force is empirical formula; experiments to explore theauthenticity of the Salomon hypothesis at a cutting speed of60m/min to350m/min the scopeof the study, the variation of Inconel718and three titanium alloys tool-chip contacttemperature do not comply with the hypothesis of Salomon; workpiece machined surfacetemperature variation according to Salomon hypothesis, the critical cutting speed80m/minnear; three cutting force the variation Inconel718and Ti-6Al-4V according to Salomonhypothesis near the critical cutting speed is still80m/min, Ti-5Al-2.5Sn ELI and Ti- 10V-2Fe-3Al do not comply with Salomon hypothesis, so Salomon hypothesis remains to beproven.Study done of this article will be optimized nickel-based superalloys and titanium alloyscutting parameters provide a useful reference data, a reasonable choice for the guidance of thehigh-speed cutting difficult materials cutting tool geometry, thereby enhancing the productivi-ty and quality of processing of difficult materials, and reduce costs, and constantly developnew products.