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Experimental and finite element study of steady state micro-cutting characteristics of aluminum alloy (2A12)

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Abstract

This paper studies the micro-cutting characteristics of aluminum alloy (2A12) based on a series of orthogonal experiments and finite element method (FEM) simulations. An energy-based ductile failure law was proposed in the FEM simulation. The simulated cutting forces and chip morphology were compared with experimental results. The simulation result indicates that there is a close relationship between the cutting force and cutting heat. The micro-cutting force decreases as the heat flux vector increases. Both the cutting heat and the micro-cutting force need a finite time to achieve a steady state. It is observed that with the cutting speed of 169.95 m/min and uncut chip thickness of 6 μm, the heat flux vector in the workpiece increases to a stable value after 0.06 ms; meanwhile, the principal cutting force decreases to a steady state correspondingly, i.e., the micro-cutting process achieves the steady state. It is concluded that the steady state micro-cutting simulation can reflect the cutting process accurately.

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Authors and Affiliations

  1. Key Laboratory of Advanced Ceramics and Machining Technology of Ministry of Education, Tianjin University, Tianjin, 300072, China

    Guang Chen  (陈 光), Chengzu Ren  (任成祖), Xinmin Jin  (靳新民) & Tao Guo  (郭 韬)

Authors
  1. Guang Chen  (陈 光)
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  2. Chengzu Ren  (任成祖)
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  3. Xinmin Jin  (靳新民)
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  4. Tao Guo  (郭 韬)
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Corresponding author

Correspondence to Chengzu Ren  (任成祖).

Additional information

Supported by the National High Technology Research and Development Program of China (“863” Program, No. 2008AA042509).

CHEN Guang, born in 1983, male, doctorate student.

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Chen, G., Ren, C., Jin, X. et al. Experimental and finite element study of steady state micro-cutting characteristics of aluminum alloy (2A12). Trans. Tianjin Univ. 17, 344–350 (2011). https://doi.org/10.1007/s12209-011-1618-0

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  • DOI: https://doi.org/10.1007/s12209-011-1618-0

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