Numerical Simulation And Experimental Study Of Processing In Turning ZL109 Aluminum Alloy

Al-Si alloy material is widely applied in aircraft,automobiles,tanks and marine engines and other industrial departments owing to its excellent comprehensive properties.But Al-Si alloy is typical difficult-to-work material with low cutting efficiency,serious tool wear,high processing cost.Therefore,it is urgent to solve the problems of studying the application of new material tool in the processing of Al-Si alloy and improving the level of Al-Si alloy processing technology.This paper carried out in-depth research on the PCD turning tool cutting ZL109 Al-Si alloy.Firstly,quasi static experiments and dynamic impact compression experiments are conducted by materials testing machine and split hopkinson pressure bar apparatus to determine the Johnson-Cook constitutive model parameters of ZL109.Secondly,with the finite element analysis software Advant Edge FEM,the influence of tool geometric parameters(rake angle,clearance angle and tool nose radius)on cutting force and the temperature of tool nose is simulated and analyzed by single factor method in the test.By using the orthogonal test method and range analysis,the combination of tool geometric parameters are selected out,so as to obtain the optimal tool structure.Thirdly,by using single factor method and orthogonal test method,simulation cutting is proceeded by the finite element analysis software for cutting parameters(feed rate,cutting depth and cutting speed).The optimal cutting parameters are obtained after range analysis.Finally,experimental verification is made for tool geometric parameters and cutting parameters.The experimental results and simulation results are compared,and the reasons of the difference are analyzed.Through the research of this paper,we not only obtain the Johnson-Cook constitutive model parameters of ZL109,but also obtain the optimal tool geometry parameters and cutting parameters through the finite element simulation.Through the experimental verification and comparative analysis,we proved that the simulation and optimization results are feasible.I hope that the research of this paper can provide areference for the Al-Si alloy machining improvement.