Optimization of Milling Aluminum Alloy 6061-T6 using Modified Johnson-Cook Model

Finite element (FE) simulation is an efficient and time-saving method to optimize the high-speed machining process of aluminum (Al) alloy. The constitutive model accurately described the dynamic mechanical behavior of materials at cutting conditions is the premise of obtaining high-precision simulation results. In this study, the flow stress-strain relationship of AA 6061-T6 is obtained at a high temperature (up to 400 degrees C) and a high strain rate (up to 1 x 10(4) s(-1)). Temperature-dependent Johnson-Cook (J-C) model is proposed by considering dynamic recrystallization effect. By the modified J-C model, a two-dimensional simplified FE model is established to optimize the high-speed milling process of AA 6061-T6 hard drive head (HDH) access arm. The results show that the modified J-C constitutive model has a good prediction accuracy, and the predicted cutting forces are in good agreement with the experimental results. By the finite element simulations, the influences of both cutting parameters and tool geometric parameters on cutting force, chip morphology, cutting temperature, effective stress and effective strain are analyzed during cutting processes of AA 6061-T6. Optimized range of cutting parameters and tool geometric parameters are obtained, which provides a theoretical guidance for the optimization of the cutting processes of Al alloy precision parts.

Automated summary

Finite element simulation is an efficient method to optimize the high-speed machining process of aluminum alloy, with a temperature-dependent Johnson-Cook constitutive model being proposed for accurate prediction. The study successfully established a two-dimensional FE model to analyze cutting forces and chip morphology, providing theoretical guidance for the optimization of cutting processes.