An improved material constitutive model for simulation of high-speed cutting of 6061-T6 aluminum alloy with high accuracy

摘要

Material constitutive model is one of the basic scientific fundamentals for simulation accuracy of high-speed cutting (HSC). A high-speed orthogonal cutting method (HS-OCM) based on the shear slip distance, aided by split Hopkinson pressure bar (SHPB) experiments, is proposed in this paper to obtain the shear slip deformation characteristics in the HSC of 6061-T6 aluminum alloy. The Johnson-Cook (JC) model was modified in three ways according to the variation tendencies of the effect curves of strain hardening, strain rate strengthening, and thermal softening, and an improved material constitutive model was obtained. The simulation validations of the obtained material constitutive models were executed. It was found that the modified JC model improves simulation accuracy, i.e., the maximum simulation errors of the cutting force and cutting temperature are 18.5 and 12.2 %, respectively. The HS-OCM avoids the cutting speed limitation (< 700 m/min) of the quick-stop test usually used in conventional OCM and the difficulty of predicting tendency inflection points of the inverse identification method employing a finite element simulation model, and allows the experimental measurement of the deformation characteristics of 6061-T6 aluminum alloy in high-speed (2000 m/min) cutting. During HSC of 6061-T6 aluminum alloy, the shear stress, shear strain rate, and deformation temperature in the primary deformation zone increase with increasing cutting speed, whereas the shear strain decreases.