Shrinkage Factor Analysis in the Dry Machining of UNS A92024 Alloy by FEM

Abstract

Chip evacuation becomes a relevant factor in the dry machining of aeronautical aluminium alloys, either when they are machined as isotropic material or hybridized with other materials. Chip morphology and geometry highly depend on cutting parameters. Several works can be found in the literature focusing on the analysis of chip morphology of aluminium alloys at high cutting speeds but there is a lack of studies that apply low cutting speeds. FEM simulation may be useful to reduce the experimental time and cost of this kind of analysis. Therefore, in this work, the influence of feed-rate on several chip geometrical parameters (height of peaks, height of valleys and shrinkage factor) of dry turned UNS A92024 alloy has been analysed by FEM simulation. Three different energy fracture modes have been tested as damage evolution criterion, in order to get the mode that better fit the experimental chip morphology. In general, the mixed mode was the fracture energy mode that best suited the chip morphology behaviour, within wider feed-rate range.