2D finite element modeling and analysis of dry turning process of aeronautic aluminium alloy 2024

The identification and selection of different physical parameters greatly influence the machining of materials. Cutting speed, feed, tool rake angle and friction are important physical parameters that affect the machining of the materials. Selection of suitable cutting parameters can help to achieve the better machining quality and enhanced tool life. Properly defined FE-model can efficiently simulate the machining processes and thus may help to save the machining cost and expensive materials instead of performing real-life experiments. In the present work, a detailed finite element analysis on the orthogonal cutting of aluminium alloy (AA2024) is conducted to validate the FE-based machining model. Numerically obtained resultant cutting forces are successfully compared with the experimental results for 0.3 and 0.4 mm/rev cutting feeds with 17.5° tool rake angle. Subsequently, the cutting forces are predicted for the selected feeds of 0.35 & 0.45 mm/rev and for different tool rake angles like 9.5°, 13.5° & 21.5° using finite element analysis. Finally, the optimum cutting parameters are suggested for cutting AA2024.