| Nickel-based alloys GH4169have a wide range of applications in the aerospaceindustry. Because of its low thermal conductivity, high friction coefficient and lowelastic modulus, nickel-based alloys is difficult to machine materials. In this paper, theresearch is on high-speed turning and high-speed milling process. Based on the finiteelement model, high-speed cutting mechanism is studied which will provide theoreticalsupport for the nickel-based alloys’ high performance machining technique. Accordingto the high-speed cutting mechanism, the cutting parameters are optimized to providetechnology support for the actual processing. The main content of this paper is asfollows:Firstly, finite element simulation of nonlinear material constitutive model, dynamicfailure criteria, and knives-chip contact friction are studied, and the problem ofnonlinear metal cutting are resolved with numerical method.Secondly, the two-dimensional and three-dimensional numerical simulation of highspeed cutting of nickel-based alloys GH4169are made by the commercial finite elementcod ABAQUS, and the simulation results are found to be in good agreement with theactual cutting process. The distribution of temperature and stress are studied in differentstages of cutting. The cutting parameters are investigated for variation of cuttingtemperature and cutting force. On the other hand，the variation of the main shear zone isobtained by analyzing variation of shear angle with different cutting depths and cuttingspeeds on the base of Oxley material cutting model for strain hardening.Finally, the simulation results of milling cutting force and temperature have beenverified by single-factor experiment. In the experiment, the variation of cutting force ismeasured by Three-Dynamometer, temperature variation is measured by the infraredthermal imager. Result shows that finite element simulation results are basicallyconsistent with the experimental results in different spindle speed conditions. |
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