Study On The Cutting Physical Simulation Of Aluminum Alloy7050-T7451Based On Material Properties And Tool-chip Friction Experiments

Metal cutting is a basic machining method in machinery manufacturing industry,which has been widely used in various production sectors of the manufacturingindustry. Physical simulation becomes a popular technology in metal-cutting because itis convenient to integrate the research achievements of the cutting mechanism.In view of the present problems in metal cutting simulation, material constitutiveequation and tool-chip friction characteristics were investigated in order to improve theaccuracy of physical simulation in metal cutting process. The main contents aboutphysical simulation method based on material constitutive equation and tool-chipfriction characteristics are listed as follows:First, the experimental strategy to obtain material constitutive parameters waspresented based on the mathematical form of the Johnson-Cook（J-C）equation.Quasi-static compression experiment and Split Hopkinson Pressure Bar (SHPB)experiment were conducted on the pressure bar experimental platform. The constitutiveparameters of aluminum alloy7050-T7451were obtained with the least squaresestimation.Second, the orthogonal cutting experiment platform was built on the basis ofmathematical model of orthogonal cutting. Matlab genetic algorithm was selected toextract the constitutive parameters of aluminum alloy7050-T7451from the orthogonalcutting experiments. Tool-chip friction characteristics in orthogonal cutting processwere analyzed in detail. The relationship between the contact length of tool-chip andfriction coefficient was established.Third, the finite element modeling of the metal cutting process and the secondarydevelopment of the AdvantEdge FEM software were accomplished on the basis oftwo-dimensional cutting simulation model. Critical influencing factors in physicalsimulation were analyzed and the aluminum alloy7050-T7451constitutive parametersfrom pressure bar experiments were optimized. Combined with the experimental data,the effectiveness of physical simulation based on material constitutive equation andtool-chip friction characteristics was verified by two-dimensional cutting process. The results show that typical characteristics of cutting process was predictedaccurately by physical simulation method proposed in this paper, the accuracy ofphysical simulation can be improved significantly when appropriate materialconstitutive equation and coefficient of tool-chip are input in the AdvantEdge FEMsoftware.