| Metal cutting process is a typical thermo-mechanical process which goestogether with the occurrence of high strain, high strain rate and instant temperatureincreasing. In the foretime, researchers find these variables by using experimentaltechniques which makes the investigation very time consuming and expensive. At thispoint, with the rapid development of computer technology, finite element modellingand simulation becomes main tool.By combination of the finite element method (FEM) and cutting technology,simulation of metal cutting can predict important variables such as temperature,cutting forces，chip plastic formation，stress and strain distributions in the cuttingprocess.The aim of this thesis paper is create a numerical model to conduct furtherresearch on metal cutting process. Based on the domestic and foreign investigatedstatus from the two dimensional (2D) orthogonal cutting and three dimensional (3D)oblique cutting principles, and the key modeling techniques of thermo-mechanicalcoupling for the simulation，a method combining theoretical analysis with finiteelement calculation and experiment is adopted in this dissertation to study thedistortion and variables prediction.1. Through Aluminum alloy7050-T7451continuous chip of2D FEM modelwas established and analyzed the distribution law of stress, strain, cuttingforce and temperature. With research purposes of serrated chip formationmechanism of titanium alloy TI-6Al-4V, the FEM model is analyzed chipformation to achieve2D simulation of serrated chip. The cutting forces arevalidated by comparing simulation results with experimental resultsavailable in the literature.2. According to the milling process of aluminum alloy7050-T7451, a3Dthermo-mechanical coupling FEM is constructed to simulate the millingprocess. The chip morphology and cutting forces of FEM model weresimilar with that obtained from experiment. Subsequently,3D milling FEMmodel with solid carbide milling cutter of aluminum alloy was established.The simulate results such as residual stress，thin-walled part machining deformations were presented and analyzed.The thesis results show that the FEM is an effective tool for simulating thecutting process. These important cutting variables can be predicted without doing anyexperiment with FEM. The simulation results are also relatively close to the actualsituation. |
