Numerical Modeling Of Metallic Materials And Machining Parameters Optimization Using FEM

Due to rapid developments of technology of computer, finite-element analysis has been utilized widely in domain of metal-cutting. Related software which was designed based on the simulation of metal-cutting has emerged in decades. Current commercial software is able to simulate common materials precisely resulting in the mature study on these material models. However many limitations of finite-element analysis software have been realized in the actual engineering issues resulting in lacking of the specific material models, especially some characteristics of new materials can be hardly obtained in these commercial software. This thesis represents further researches on the mechanism of the metal chip deformation, structure the material constitutive model and secondary development technology of finite-element simulation in cutting process. Series valid strategies of optimizing the cutting parameters are proposed.A subprogram of ABAQUS, which is also called Vumat, has been developed by FORTRAN based on the finite-element theory, plastoelasticity and fracture mechanics in the research. Johnson-Cook constitutive model and failure criterion is reconstructed in the subprogram while its validation is verified by comparing simulation of material extending to ABAQUS.ABAQUS and AdvantEdge are utilized separately in the simulation of two-dimension orthogonal cutting in aluminum alloy 6061 machining. Particularly the simulations processed in ABAQUS use Vumat subprogram as a mainly method, furthermore a simulation comparison scheme is designed in the paper, which verifies the precision of the Vumat through the comparison between parameters such as calculating cutting force, temperature of cutting, stress and chip shape in these two software.By operating finite-element simulations to finish boring in crankshaft hole of engines authorized by SGMW and optimizing the machining parameters through simulation comparisons, the experiment shows an impressive outcome including tool wear decrease, reductions of burr issues as well as efficiency increase.