Skip to main content
SpringerLink
Log in

FEM simulation-based cutting parameters optimization in machining aluminum-silicon piston alloy ZL109 with PCD tool

  • Published:
Journal of Mechanical Science and Technology Aims and scope Submit manuscript

Abstract

The Johnson-Cook (JC) constitutive model was utilized to simulate the processing of Al-Si piston alloy ZL109 to obtain the optimal finishing parameters in polycrystalline diamond (PCD) tool, and studied the machining quality of ordinary-turning under the optimized cutting parameters. PCD is brittle, so it is difficult to manufacture orthogonal blades and is easy to break and high cost. We have adopted ordinary-turning quality to verify simulation results. Effect of cutting parameters on residual stress, cutting force and temperature was investigated through simulation, meanwhile, effect of cutting parameters on surface roughness and residual stress was analyzed by experiments. It indicates the verification method is practicable, and residual stress, cutting force and temperature are the smallest in simulation, and the experimental values of surface roughness and residual stress are also the smallest under the optimal cutting parameters, which can guide the cutting parameters selection to obtain higher machining quality.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. D. L. Liu and P. X. Qi, New Aluminum Piston, National Defense Industry Press, Beijing, China (1999).

    Google Scholar 

  2. J. T. Carroll Iii and J. S. Strenkowski, Finite element models of orthogonal cutting with application to single point diamond turning, International Journal of Mechanical Sciences, 30 (12) (1988) 899–920.

    Article  Google Scholar 

  3. S. D. Wang, Finite Element Simulation and Experimental Study on Cutting Process of Medical Titanium Alloy, M.S. Dissertation, Nanjing University of Science and Technology, China (2010).

    Google Scholar 

  4. Z. C. Gong, Research on Optimization of Aluminum Alloy Piston Pin Hole Machining Process, M.S. Dissertation, Shandong University, China (2015).

    Google Scholar 

  5. Z. P. Xu, Research on Key Technology of Dynamic Physics Simulation of Cutting Process based on Finite Element Method, M.S. Dissertation, Shandong University, China (2008).

    Google Scholar 

  6. F. Cus and J. Balic, Optimization of cutting process by GA approach, Robotics and Computer-Integrated Manufacturing, 19 (1) (2003) 113–121.

    Article  Google Scholar 

  7. J. Zhao et al., Tool life study and cutting parameter optimization of ultra-high speed cutting Inconel 718, Journal of Harbin University of Science and Technology, 16 (1) (2011) 9–12.

    Google Scholar 

  8. P. F. Zhao, Research and Development of Hole Machining Cutting Parameter Optimization System, M.S. Dissertation, Nanjing University of Science and Technology, China (2013).

    Google Scholar 

  9. Z. J. Zhou and H. J. Kang, Optimization of tool geometries of PCD tool for turning ZL109 through FEM simulation, Journal of Hunan University of Science & Technology (Natural Science Edition), 32 (2) (2017) 15–21.

    MathSciNet  Google Scholar 

  10. A. H. Li et al., Process optimization of aluminum alloy piston pin hole machining process, Manufacturing Technology & Machine Tool, 2 (2018) 33–36.

    Google Scholar 

  11. G. M. Hou et al., Effect of cutting parameters on surface quality in multi-step turning of Ti-6Al-4V titanium alloy, The International Journal of Advanced Manufacturing Technology, 98 (5-8) (2018) 1355–1365.

    Article  Google Scholar 

  12. J. H. Zhang and Z. H. Shang, Sharpening and geometric parameters of PCD cutters for turning silicon-aluminum alloy pistons, Journal of Shandong University (Engineering Science), 35 (5) (2005) 5–8.

    Google Scholar 

  13. Y. Wang et al., High temperature fatigue analysis of ZL109 cast aluminum alloy, Research and Exploration in Laboratory, 139 (10) (2007) 203–205.

    Google Scholar 

  14. J. X. Deng and J. Zhao, CNC Tool Material Selection Manual, Mechanical Industry Press, Beijing, China (2005).

    Google Scholar 

  15. W. Zhang, Factors Affecting the Accuracy of Piston Machining in Internal Combustion Engines, M.S. Dissertation, Xi’an University of Science and Technology, China (2017).

    Google Scholar 

  16. J. Fu, Physical Simulation and Experimental Research on the Cutting Process of Difficult to Cut Metallic Material, M.S. Dissertation, Hunan University, China (2013).

    Google Scholar 

  17. K. L. Li, Mechanical Manufacturing Technology, Shandong Science and Technology Press, Ji’nan, China (2005).

    Google Scholar 

  18. Y. Chen, H. Li and J. Wang, Further development of ox-ley’s predictive force model for orthogonal cutting, Machining Science & Technology, 19 (1) (2015) 86–111.

    Article  Google Scholar 

  19. G. L. Coz and D. Dudzinski, Temperature variation in the workpiece and in the cutting tool when dry milling Inconel 718, The International Journal of Advanced Manufacturing Technology, 74 (5–8) (2014) 1133–1139.

    Article  Google Scholar 

  20. S. Y. Wang et al., Finite element simulation of cutting speed on residual stress on workpiece surface, Tool Engineering, 39 (9) (2005) 33–36.

    Google Scholar 

  21. E. Usui et al., Cutting and Grinding, Mechanical Industry Press, Beijing, China (1982).

    Google Scholar 

  22. A. H. Li et al., Design and simulation of thermal residual stresses of coatings on WC-Co cemented carbide cutting tool substrate, Journal of Mechanical Science and Technology, 30 (8) (2016) 3777–3783.

    Article  Google Scholar 

  23. S. V. Telrandhe, A. K. Saxena and S. Mishra, Effect of microstructure and cutting speed on machining behavior of Ti6Al4V alloy, Journal of Mechanical Science and Technology, 31 (5) (2017) 2177–2184.

    Article  Google Scholar 

  24. S. Masoudi et al., Effect of machining-induced residual stress on the distortion of thin-walled parts, The International Journal of Advanced Manufacturing Technology, 76 (1–4) (2015) 597–608.

    Article  Google Scholar 

  25. O. Fergani et al., Analytical modeling of residual stress and the induced deflection of a milled thin plate, The International Journal of Advanced Manufacturing Technology, 75 (1–4) (2014) 455–463.

    Article  Google Scholar 

  26. T. Jia et al., Study on cutting property of machining aluminum alloy in PCD tool based on orthogonal experiment, Light Alloy Fabrication Technology, 35 (1) (2007) 46–48.

    MathSciNet  Google Scholar 

  27. F. Shao et al., Diffusion wear of ZL109 aluminum alloy processed by PCD tool based on thermodynamics, Journal of Tianjin University (Natural Science and Engineering Technology Edition), 43 (4) (2010) 315–321.

    Google Scholar 

Download references

Acknowledgments

This work was supported by the National Natural Science Foundation of China (51605260), the Key Research and Development Program of Shandong Province - Public Welfare Special (2017GGX30144, 2018GGX103043) and the Young Scholars Program of Shandong University (2018WLJH57).

Author information

Authors and Affiliations

  1. Key Laboratory of High Efficiency and Clean Mechanical Manufacture of MOE, School of Mechanical Engineering, Shandong University, Jinan, 250061, China

    Yonghui Zhou, Hu Sun, Anhai Li, Minghang Lv, Chaoyi Xue & Jun Zhao

  2. National Demonstration Center for Experimental Mechanical Engineering Education, Shandong University, Jinan, 250061, China

    Yonghui Zhou, Anhai Li & Jun Zhao

Authors
  1. Yonghui Zhou
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Hu Sun
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Anhai Li
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Minghang Lv
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Chaoyi Xue
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Jun Zhao
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Anhai Li.

Additional information

Recommended by Associate Editor Seok-min Kim

Yonghui Zhou, born in 1973, is currently an Associate Professor at School of Mechanical Engineering, Shandong University, Jinan, China. He received his B.E. degree in chemical machine from Shandong University of Technology, Ji’nan, China in 1994 and his Ph.D. degree in mechanical manufacturing and automation from Shandong University, Jinan, China in 2009. His research interests include high efficient machining & NC tool technology.

Anhai Li, born in 1984, is currently an Associate Professor at School of Mechanical Engineering, Shandong University, Jinan, China. He received his B. E. degree in mechanical engineering and automation from Jilin University, Changchun, China in 2008 and his Ph.D. degree in mechanical manufacturing and automation from Shandong University, Jinan, China in 2013. His research interests include high efficient machining and numerical control cutting tool technology. He is the member of American Society of Mechanical engineers (ASME) and Chinese Mechanical Engineering Society (CMES).

Jun Zhao, born in 1967, is currently a Professor at School of Mechanical Engineering, Shandong University, Jinan, China. He received his B.E. degree, M. E. degree and Ph.D. degree in mechanical engineering from Shandong University of Technology, Jinan, China in 1989, 1993 and 1998, respectively. His research interests include high efficient machining & NC tool technology and multi-axis CNC machining technology of complex curved surface. He is the member of Chinese Mechanical Engineering Society (CMES).

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Zhou, Y., Sun, H., Li, A. et al. FEM simulation-based cutting parameters optimization in machining aluminum-silicon piston alloy ZL109 with PCD tool. J Mech Sci Technol 33, 3457–3465 (2019). https://doi.org/10.1007/s12206-019-0640-3

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s12206-019-0640-3

Keywords

Search

Navigation