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Metals 2016, 6(9), 197; doi:10.3390/met6090197

Dry Machining Aeronautical Aluminum Alloy AA2024-T351: Analysis of Cutting Forces, Chip Segmentation and Built-Up Edge Formation

1
LEMTA CNRS-UMR 7563, Lorraine University, Mines Albi, Mines Nancy, GIP-InSIC, 27 rue d’Hellieule, 88100 Saint-Dié-des-Vosges, France
2
LEM3 CNRS-UMR 7239, Lorraine University, Ile du Saulcy, 57045 Metz, France
*
Author to whom correspondence should be addressed.
Academic Editor: Nong Gao
Received: 10 June 2016 / Revised: 28 July 2016 / Accepted: 11 August 2016 / Published: 24 August 2016
(This article belongs to the Special Issue Aluminum Alloys)
View Full-Text   |   Download PDF [6024 KB, uploaded 24 August 2016]   |  

Abstract

In this paper, machining aeronautical aluminum alloy AA2024-T351 in dry conditions was investigated. Cutting forces, chip segmentation, and built-up edge formation were analyzed. Machining tests revealed that the chip formation process depends on cutting conditions and tool geometry. So continuous and segmented chips are generated. Under some cutting conditions, built-up edge formation occurs. A predictive machining theory, based on a finite elements method (FEM), was applied to reproduce and explain these phenomena. Thermomechanical behaviors of the work material and the tool-work material interface were considered. Results of the proposed modelling were compared to experimental data for a wide range of cutting speed. It was shown that the feed force is well reproduced by the ALE-FE (arbitrary lagrangian-eulerian finite element) formulation and highly underestimated by the lagrangian finite element (LAG-FE) one. While, the periodic localized shear band, leading to a chip segmentation, is well reproduced with the Lagrangian FE formulation. It was found that the chip segmentation can be correlated to the cutting force evolution using the defined chip segmentation intensity parameter. For the built-up edge (BUE) phenomenon, it was shown that it depends on the contact/friction at the tool-chip interface, and this is possible to simulate by making the friction coefficient time-dependent. View Full-Text
Keywords: aluminum alloy AA2024-T351; dry machining; cutting/feed forces; chip segmentation; built-up edge; FE modeling aluminum alloy AA2024-T351; dry machining; cutting/feed forces; chip segmentation; built-up edge; FE modeling
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This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited. (CC BY 4.0).

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MDPI and ACS Style

Haddag, B.; Atlati, S.; Nouari, M.; Moufki, A. Dry Machining Aeronautical Aluminum Alloy AA2024-T351: Analysis of Cutting Forces, Chip Segmentation and Built-Up Edge Formation. Metals 2016, 6, 197.

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