Investigations on machining characteristics and chip morphology in turning Al-Mn (AM) alloy using finite element simulation

Abstract

Finite element analysis has become an indispensable tool, often used in research and development, to provide valuable insights into the process. The studies in the metal cutting area mostly employ the Finite element method (FEM) due to its ability to highlight the physics involved in chip formation and the range of force generated in the cutting zone. The study involves investigations by adopting the Johnson-Cook (JC) constitutive model with energy-based damage criteria to simulate the turning of a fabricated AM (Mg alloy: 7 wt%Al-0.9 wt%Mn) alloy. For the FEM, the JC and Damage model constants are calculated using inverse identification methodology. The results obtained on the cutting force (F_c), cutting temperature (T_c), and chip-thickness (t_c) at different combinations of turning parameters were analyzed and compared with the experimental values. The Predicted data was in line with the experimental data, and a variation of mostly less than 12% was observed. Thus, establishing the efficacy of inverse identification method. Further, the obtained results exhibit the significant influence of turning parameters on F_c(N), T_c(°C), and t_c(mm) and enunciates crucial facts related to the AM alloy's machinability.

Keywords

AM alloy Finite Element simulation constitutive force temperature chip-thickness

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