Simulation and experimental studies to verify the effect of cutting parameters on chip shrinkage coefficient and cutting forces in machining of A6061 aluminum alloy

Abstract

This article predicts the relationship between chip shrinkage coefficient and cutting parameters such as cutting speed and uncut chip thickness in a cutting process of A6061 aluminum alloy. To this end, shrinkage coefficient-based finite element method was first estimated using the Johnson-Cook (J-C) and Bao-Wierzbicki (B-W) material fracture models. After that, experimental measurements of the chip shrinkage coefficients were performed at the same cutting conditions to compare with simulation data and confirm the accuracy of material damage models. By a simultaneous evaluation of the effects of cutting parameters on the chip shrinkage coefficient, the B-W model was found to match well with the experiment. So that, the B-W model was then utilized to verify the effect of various cutting speeds and uncut chip thicknesses on the chip shrinkage coefficient and cutting force. Finally, using the least square method, the relationship between chip shrinkage coefficient and cutting force was obtained. The above-mentioned relationship is believed to be useful in determination of optimal cutting conditions in high-speed machining.

Assessment of Factors Affecting Social Insurance Management by Analytic Hierarchy Process Method

“…The influencing factors are inherited from previous studies in the field of social insurance such as Do Van Sinh [5] and Pham Thi Hoa [7]. Based on the actual situation of the collection of social insurance and health insurance of the Social Insurance of Tien Giang Province from the perspective of the Board of Directors and experts in the field of social insurance, this study proposes four basic elements.…”

Cutting Force Model for Thermal-Assisted Machining of Tool Steel Based on the Taguchi Method

“…With nine-point experimental data in machining at elevated temperatures, the nonlinear regression function in thermal-assisted milling of SKD11 steel was defined as in Equation (12). The error percentage of the comparison with the experimental data was evaluated according to Equation (10). The results are shown in Table 13.…”

“…In practice, the cutting forces are very important to the design of cutting tools, fixture, calculation, and design machine. Under effect of the cutting forces and cutting temperature, the tool will be worn or destroyed [10]. Ginta et al [11] presented the effectiveness of thermal-assisted machining on machinability in end milling of Ti-6Al-V4 material.…”

Experimental study on the chip morphology, tool–chip contact length, workpiece vibration, and surface roughness during high-speed face milling of A6061 aluminum alloy

“…Huang et al 18 proposed a regression equation, which reflected the relationship between the cutting parameters and the residual stresses during high-speed end milling of the 7050-T7451 aluminum alloy. Pham et al 19 also proposed equations for cutting force and chip shrinkage coefficient in milling of the A6061 aluminum alloy. Kazban et al 20 measured cutting forces and temperature distribution at the tool tip in high-speed orthogonal machining of 6061-T6 aluminum alloy using a modified Hopkinson bar apparatus.…”