Title: Finite element simulation and experimental analysis of orthogonal cutting of an aluminium alloy using Polycrystalline Diamond tools

Authors: J. Paulo Davim, P. Reis, C. Maranhao, M.J. Jackson, G. Cabral, J. Gracio

Addresses: Department of Mechanical Engineering, University of Aveiro, Campus Santiago, 3810-193 Aveiro, Portugal. ' Department of Mechanical Engineering, University of Aveiro, Campus Santiago, 3810-193 Aveiro, Portugal. ' Department of Mechanical Engineering, University of Aveiro, Campus Santiago, 3810-193 Aveiro, Portugal. ' Centre of Advanced Manufacturing, College of Technology, Purdue University, West Lafayette, IN 47907-2021, USA. ' Department of Mechanical Engineering, University of Aveiro, Campus Santiago, 3810-193 Aveiro, Portugal. ' Department of Mechanical Engineering, University of Aveiro, Campus Santiago, 3810-193 Aveiro, Portugal

Abstract: The current paper presents a Finite Element Model (FEM) simulation and experimental analysis of orthogonal cutting on aluminium alloy using Polycrystalline Diamond (PCD) tools. FEM machining simulations used a Lagrangian finite element-based machining model, Advantedge^TM, applied to predict cutting forces, temperature distribution, plastic strain, von Mises and maximum shear stresses. The orthogonal cutting model was validated by comparing cutting forces obtained experimentally with a thermo-mechanical FEM analysis under orthogonal cutting conditions. Finally, FEM analysis prediction of the evolution of plastic strain, von Mises stress and maximum shear stresses during the machining of a commonly used aluminium alloy using PCD tools was conducted.

Keywords: FEM; finite element method; machining simulation; PCD tools; aluminium alloys; polycrystalline diamond; orthogonal cutting; modelling; cutting forces; plastic strain; von Mises stress; maximum shear stress.

DOI: 10.1504/IJMPT.2010.029458

International Journal of Materials and Product Technology, 2010 Vol.37 No.1/2, pp.46 - 59

Published online: 30 Nov 2009 *

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