Experimental Investigation and Comparison of Output Cutting Regimes with Finite Element Machining Models for SiCp Based Al7075 Composite

• Published in: SILICON 2022-02, Vol.14 (3), p.883-892
• Main Authors: Setia, Sunil, Chauhan, Sant Ram
• Format: Article
• Language: English
• Subjects: Aluminum base alloys; Chemistry; Chemistry and Materials Science; Comparative studies; Cutting force; Cutting parameters; Environmental Chemistry; Feed rate; Finite element method; Geometry; Industrial applications; Inorganic Chemistry; Lasers; Machining; Materials Science; Mathematical models; Optical Devices; Optics; Original Paper; Particulates; Photonics; Polymer Sciences; Silicon carbide; Temperature distribution; Two dimensional models
• ISSN: 1876-990X; 1876-9918
• DOI: 10.1007/s12633-020-00887-3

The purpose of this research is to perform a comparative study by considering two different types of finite element models (FEM) in order to predict the output cutting regimes i.e. main cutting force and cutting temperature in machining operation. Further, these developed models are compared with the experimental data as well. A two-dimensional FEM model has been made by assuming plain strain condition to cut down the simulation cost. The finite element-based model has been developed by taking coupled temperature distribution with two different types of the position of reinforcing particle (SiC) in the Al7075 matrix i.e. uniform and zigzag. For material modeling purposes in ABAQUS software, the Johnson cook damage and evolution model has been used by varying feed rates under orthogonal cutting conditions. It is depicted from the results that model prediction errors for main cutting force (F c ) and cutting temperature (T t ) are 12.9 and 12% respectively for uniformly distributed particulates. Further, these prediction error values in the case of zigzag distribution of particulates values are 11.2% and 5.7% for F c and T t respectively. Results depicted from the comparison that the experimental results are in fair agreement with the developed FEM model values, however, Al7075 composite with zigzag SiC particle distribution gives improved results in terms of precision. The obtained models can predict machining output values with fair accuracy and these can be utilized to increase the machining database at low cost for industrial use.