Finite Element Simulation And Experimental Research Of Cutting For Aluminum Alloy 6061-T6 On Adhesion Phenomenon

With the rapid development of technology of high-speed railway and aviation,6061 aluminum alloy is widely used for the production of high speed train and bullet train because of light weight,corrosion resistance,good appearance,and easy to manufacture welding for complex surface and other advantages.The aluminum alloy is soft and sticky,so it is very easy to produce the adhesion behavior in the cutting process.The adhesion behavior of aluminum alloy is also directly resulted in the built-up edge of the tool than other metal materials.On the other hand,with the rapid development of computer technology,finite element technology has been widely used in the field of metal cutting.The finite element simulation technique is used to simulate the machining process by establishing the geometric model of the tool and the workpiece.According to the process of milling tool trochoid motion prediction of undeformed chip shape,based on the finite element analysis software Abaqus and AdvantEdge FEM,the paper establishes the finite element model of 6061-T6 aluminum alloy with the adhesion phenomenon and carried on the verification experiment.Comparison of the experimental data and the model prediction results of three aspects of the milling force,milling temperature and chip morphology.The temperature measurement verification process in milling experiment by semi artificial thermocouple method,the thin constantan band instead of Constantan wire,can greatly compensate for the lack of traditional semi manual thermocouple method can only measure the milling process at one point in the instantaneous temperature,increases the temperature measurement scope,effectively improve the measurement accuracy and measurement accuracy of response.After the milling experiment,the influence degree of different cutting tools and milling parameters on milling process can be measured by measuring the height of the built-up edge.The data of three direction milling force and temperature were obtained in the experiment.The influence of milling parameters and tool parameters on milling force and temperature was analyzed by range analysis.For X direction milling force,the axial cutting depth of the influence coefficient is the highest,the influence coefficient of the spindle speed is the lowest,followed by each tooth feed rate and radial cutting depth.For the Y direction milling force,the spindle speed influence coefficient is the highest,Radial cutting depth is the lowest.The extent of the influence of milling temperature is:the spindle speed>the feed per tooth>axial depth>radial cut.The optimal experiimental scheme is obtained for the spindle speed is 7000r/min,the feed per tooth is 0.2mm,the radial cutting depth and the axial cutting depth are 1mm.The results show that the milling finite element model of 6061-T6 Aluminum Alloy considering adhesion phenomenon prediction of milling force error is less than 10.3%,milling temperature eiTOr of less than +12%,with the chip shape comparison,prediction results are better than the model without considering the adhesion phenomenon results.Verify the accuracy of the finite element model considering the adhesion phenomenon.The establishment of finite element model will help reduce tool wear,prolong the service life of the cutter and explore the optimum machining process parameters,save a lot of materialL labor and time cost which has an important guiding significance to the production practice.