Finite Element Modeling And Experimental Study Of Cutting Force In Ultra-precision High-speed Machining

Compared with conventional cutting,high-speed cutting reduces cutting forces with increased material removal rate.The lack of consideration of the characteristics of high strain and high-strain rate in the high-speed cutting process,deteriorates the corresponding simulation accuracy.Therefore,in this paper,an intrinsic structure model considering strain energy damage is established to study the cutting forces during high-speed cutting in ultra-precision machining.The main contents can be sμmmarized as follows:Firstly,based on the J-C(Johnson-Cook)intrinsic structure model,the intrinsic structure equations of Al6061 material are obtained by considering the strain energy damage during high-speed cutting.The finite element model is built by the VΜMAT under secondary development subroutine of ABAQUS finite element software.Secondly,a finite element simulation based on the intrinsic model of strain energy damage is performed to analyze the mesh distortion problem in the finite element simulation of high-speed cutting.The sawtooth-shaped chips brought by the adiabatic shear effect are obtained.Combining the cutting force and the temperature variation of the machined surface,the Salomon hypothesis is verified under high-speed cutting.Finally,the high-speed cutting force of ultra-precision machining is measured by high-precision KISTLER force measuring instrμment to analyze the cutting force decrease during high-speed cutting.Compared with the results of the previous finite element simulation,the reasonableness of the strain energy damage intrinsic model for simulating the high-speed cutting process is verified.By further evaluating the effect of depth of cut change on cutting forces,the weakening effect of depth of cut reduction on the adiabatic shear effect is found.Overall,a finite element model based on strain energy damage is established concerning the change of cutting force in the high-speed cutting.The proposed theoretical model is verified through simulation and experiment.The study can promote the development of high-speed cutting in ultra-precision machining.