Turning modeling and simulation of an aerospace grade aluminum alloy using two-dimensional and three-dimensional finite element method

This article presents the development of two-dimensional and three-dimensional finite element–based turning models, for better prediction of chip morphology and machined surface topology. Capabilities of a commercial finite element code Abaqus®/Explicit have been exploited to perform coupled temperature–displacement simulations of an aerospace grade aluminum alloy A2024-T351 machining. The findings show that two-dimensional cutting models predict chip morphologies and machined surface textures on a plane section (with unit thickness) passing through the center of workpiece width, and not at the edges. The contribution highlights the importance of three-dimensional machining models for a close corroboration of experimental and numerical results. Three-dimensional cutting simulations show that a small percentage of material volume flows toward workpiece edges (out of plane deformation), augmenting the contact pressures at the edges of tool rake face–workpiece interface. This enhances the burr formation process. Computational results concerning chip morphologies and cutting forces were found in good correlation with experimental ones. In the final part of the article, numerical simulation results with a modified version of a particular turning tool have been discussed. It has been found that the proposed geometry of the tool is helpful in reducing burr formation as well as cutting force amplitude during initial contact of cutting tool with the workpiece material