Finite Element Modeling And Simulation Research Of Typical Aviation Materials Machining

In the aerospace manufacturing industry, higher limites is required to the properties of aviation materials. Aluminum alloy and titanium alloy have low density and high strength. They are always the first selection of the aviation materials for important parts and components in an aircraft. And most of them need cutting processing in their productions. Cutting is a complicated non-linear process of thermal-mechanical coupling. The traditional experimental method was applied to determine the optimum parameters of cutting processing. The cost is high, and time-consuming. It is proved that a lot of manual labors and much materials can saved by applying finite element simulation method, The important data, deduced from the finite element simulation, has very high value on the guidance of the production practice,while the data is difficult to obtained from the experiment.Based on the finite element software ABAQUS, Python script language is used for cutting process analysis module development. The module can be parameterized to establish cutting model. Cutting process simulation can be implemented according to the input information of the workpiece, the of cutting tools and cutting parameters. This paper introduces in detail the input operation process of the geometry model creating, the cutting parameters input, selection of workpiece material, the grid parameters input and the operation parameters input. The script development of the kernel parameter input module is also detailed. Simulations are implemented for cutting processes of aluminum alloy 7050-T7451 and titanium alloy Ti-6Al-4V. The simulation results discover the chip formation laws and the variation patterns of the cutting force, cutting temperature and distribution. With the metal cutting theory, the effects of tool rake angle on cutting force and the effects of cutting speed on cutting temperature are discussed in particular. The effects of tool rake angle on the chip morphology of the two kinds of materials of are comparated and analyzed. The simulation results show that the tool before helps to improve the cutting process, machining Ti-6Al-4V, the cutting tool rake Angle, generally between 0°-8°,and the reasonable processing of 7050 rake Angle range should be 8°- 16°.