Finite Element Simulation And Experimental Research Of High-Speed Cutting For Aluminum Alloy 6061

Aluminum alloy 6061 has many advantages in terms of performance, such as high strength, good plasticity and corrosion resistance. Milling is a method, which are frequently used in aluminum alloy processing. The high speed machining are widely used because of its high machining precision and machining efficiency. In this article, the finite element simulation was mainly used to research the high speed machining for aluminum alloy 6061. Then the simulation results were summarized and analyzed, providing theory analysis and technical guidance on the further research of aluminum alloy.The high speed milling for aluminum alloy is a very complicated nonlinear process. A finite element method is a very common method to study the problem. In this paper, based on the theory of plastic deformation and the yield criterion of metal materials, providing a basis for establishing the finite element model. At the same time, the influence of external factors on the metal plasticity were studied, and the finite element simulation of metal cutting was described.According to the actual size of the milling cutter, the part of milling cutter model was set up through 3D software-Solidvvorks. The Johnson-Cook model was chosen as the constitutive model of high speed milling for aluminum alloy 6061. So as to provide a theoretical basis for the finite element simulation analysis. Then based on finite element simulation software DEFORM-3D to design the four elements of cutting parameters which was 16 groups schemes for orthogonal simulation research. The ultimate goal of the simulation was to obtain the variation of the force and temperature and the distribution of the stress and strain of the workpiece and tool under different parameters.By changing cutting parameters and tool geometric parameters, making a high speed milling of orthogonal experiment for aluminum alloy 6061. The purpose of this experiment was to verify the simulation results. It was proved that the simulation results have good consistency with the experimental results, which showed the accuracy of the finite element simulation. Obtained the data of milling force and temperature from the experiment, and then by using the method of extreme difference analyzed the cutting parameters which influenced on the milling force and temperature significantly. The last, the surface morphology of aluminum alloy scraps was observed through the SEM experiment, compared with the chip surface morphology under different temperature and strain rate, In order to obtain the plastic deformation under different conditions.