Simulation Studies of Turning of Aluminium Cast Alloy Using PCD Tools

Abstract This study investigates the influence of cutting parameters on longitudinal turning of high Silicon cast aluminium alloy AlSi9Cu3 using PCD tools with and without chip breaker geometry. In order to build the 3D numerical model, the experimental and predicted cutting forces were used for inverse calibration of the Johnson–Cook material model which was implemented in DEFORM TM finite element software. A sensitivity analysis has been performed in order to obtain an acceptable prediction of the machining parameters such as chip geometry and cutting forces as well as to understand the influence of friction and mesh size effects in the predicted results. Results have shown a satisfactory correlation between experimental turning data and numerical estimates based on assumptions that have been taken for the material behaviour.