Prediction of mechanical behavior and microstructure evolution of shear zone in orthogonal cutting 6061-T6 aluminum alloy

被引：0
|
作者：
Zhou T. [1 ]
He L. [1 ,2 ]
Tian P. [1 ]
Du F. [1 ,3 ]
Wu J. [1 ]
机构：
[1] College of Mechanical Engineering, Guizhou University, Guiyang
[2] School of Mining and Civil Engineering, Liupanshui Normal College, Liupanshui
[3] Key Laboratory of Advanced Manufacturing Technology of Ministry of Education, Guizhou University, Guiyang
来源：
Hangkong Xuebao/Acta Aeronautica et Astronautica Sinica | 2021年 / 42卷 / 03期
基金：
中国国家自然科学基金;
关键词：
6061-T6 aluminum alloy; Cutting force; Dislocation density; Grain size; Microstructure; Shear zone;
D O I：
10.7527/S1000-6893.2020.23975
中图分类号：
学科分类号：
摘要：
Mechanical behavior is the macroscopic expression of the microscopic process of plastic deformation. Early metal cutting theoretical models did not consider the effect of microstructure on the cutting force. Based on the dislocation density material model, a 6061-T6 aluminum alloy orthogonal cutting force prediction model is established, and the influence of dislocation motion based plastic deformation mechanism on the cutting force with different cutting parameters is analyzed. By combining the model of equal division shear zones and unequal division shear zones, we construct a multi-physics field calculation method for the first deformation zone, and propose an analytical model of microstructure evolution caused by plastic deformation during chip formation. The feasibility of the model is preliminarily verified by measuring the cutting force and the size of grain in the chip. The results show that the material increase involved in the dislocation slip caused by the length of the shear zone is the main reason for the increase of the feed rate, which further leads to the increase of the cutting force. The decrease in the cutting force caused by the increasing cutting speed is not the result of a single variable, but the joint effect of the number reduction of dislocations induced by the strain reduction and the annihilation increase resulted from temperature increase. The non-divided shear zone model correctly reflects the temperature and stress distribution characteristics of the first deformation zone, and is consistent with the two-dimensional finite element model. The analytical model of the microstructure evolution of the first deformation zone can predict the dislocation density and grain size in the chip. © 2021, Beihang University Aerospace Knowledge Press. All right reserved.
引用
收藏
相关论文
共 32 条
  • [1] MERCHANT M E., Mechanics of the metal cutting process. I. orthogonal cutting and a type 2 chip, Journal of Applied Physics, 16, 5, pp. 267-275, (1945)
  • [2] HILL R., The mechanics of machining: A new approach, Journal of the Mechanics and Physics of Solids, 3, 1, pp. 47-53, (1954)
  • [3] LEE E., The theory of plasticity applied to a problem of machining, Journal of Applied Mechanics, 18, (1951)
  • [4] LIU R, SALAHSHOOR M, MELKOTE S N, Et al., A unified material model including dislocation drag and its application to simulation of orthogonal cutting of OFHC copper, Journal of Materials Processing Technology, 216, pp. 328-338, (2015)
  • [5] PAN Z P, SHIH D S, TABEI A, Et al., Modeling of Ti-6Al-4V machining force considering material microstructure evolution, The International Journal of Advanced Manufacturing Technology, 91, 5-8, pp. 2673-2680, (2017)
  • [6] WU H, MA J F, LEI S T., FEM prediction of dislocation density and grain size evolution in high-speed machining of Al6061-T6 alloy using microgrooved cutting tools, The International Journal of Advanced Manufacturing Technology, 95, 9-12, pp. 4211-4227, (2018)
  • [7] DING H T, SHEN N G, SHIN Y C., Modeling of grain refinement in aluminum and copper subjected to cutting, Computational Materials Science, 50, 10, pp. 3016-3025, (2011)
  • [8] BAMMANN D J, CHIESA M L, JOHNSON G C., Modeling large deformation and failure in manufacturing processes, Theoretical and Applied Mechanics, 9, pp. 359-376, (1996)
  • [9] GUO Y B, WEN Q, WOODBURY K A., Dynamic material behavior modeling using internal state variable plasticity and its application in hard machining simulations, Journal of Manufacturing Science and Engineering, 128, 3, pp. 749-759, (2006)
  • [10] FOLLANSBEE P S, KOCKS U F., A constitutive description of the deformation of copper based on the use of the mechanical threshold stress as an internal state variable, Acta Metallurgica, 36, 1, pp. 81-93, (1988)
1234