FEM modelling of turning of AA6061-T6: Investigation of chip morphology, chip thickness and shear angle
Keywords:AA6061-T6, Finite element method, Chip morphology, Chip thickness, Shear angle
AA6061-T6 alloy, which is one of the widely used Al-Cu alloys in industry, is typically used to produce engineering parts by machining. The machining large parts consists of several turning operations. Recently, designers use a finite element modelling (FEM) to decrease the number of experiments and optimize parts during the design step to achieve higher quality products. In this study, the influences of machining parameters on the chip morphology, chip thickness and shear angles in turning of AA6061-T6 alloys are investigated by FEM. The machining parameters are selected as feed rate with four levels (0.06, 0.09, 0.12, 0.16 mm/rev), cutting speed with two levels (100 and 250 m/min) and constant depth of cut. The finite element analysis (FEA) of chip morphology, chip thickness and shear angle are conducted with Advantedge software. The results show that increasing feed rate resulted in an increase in the chip thickness and shear angle. Moreover, increasing cutting speed led to increase in shear angle, while decrease in chip thickness. Finally, based on the FEM simulation results, the deviation between experimental and simulation results were determined as 6.44% and 5.67% for chip thickness and shear angle, respectively.
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