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ABSTRACT
The goal of this study was to use constitutive models based on experimental data to predict cutting parameters in the turning of aluminium metal matrix nanocomposite (AMMNC). Using the stir casting process, the composite is made by reinforcing multiwall carbon nanotubes of 2% weight with aluminium 7075. Turning tests are carried out on work material using the Taguchi experimental design (L16) at various speeds, feeds, and depths of cut, and the output responses of cutting force, thrust force, and temperatures are recorded. Following that, Oxley’s model is used to calculate dynamic parameters such as strain, strain rate, temperature, and tool chip interfacial friction based on orthogonal experimental measurements, and the JC model is used to calculate flow stress using the values acquired from Oxley’s model. Finally, 2D-Deform software was used to do FEM simulations. The findings of 2D-Deform software, such as flow stress, temperature, and tool chip interfacial friction, are compared to the results of constitutive models, and the comparison is found to be adequate. The current research proposes an improved methodology for estimating dynamic characteristics in composite materials under various cutting situations.
Disclosure statement
No potential conflict of interest was reported by the author(s).
Nomenclature
| C | = | Strain rate sensitivity constant in the Johnson Cook constitutive model |
| C0 | = | Strain rate constant proposed by Oxley |
| FC, FT | = | Cutting and thrust force components (N) |
| K | = | Work material thermal conductivity (W/m°C) |
| KAB | = | Shear flow stress on AB (N/mm2) |
| lAB | = | Length of the primary shear zone (mm) |
| m | = | Thermal softening parameter in the Johnson-Cook constitutive model |
| n | = | Strain-hardening parameter in the Johnson-Cook constitutive model |
| pA, pB | = | Hydrostatic stresses at the points A, B(N/mm2) |
| RT | = | Non-dimensional thermal number |
| S | = | Specific heat of work material (J/kg°C) |
| T0 | = | Initial work material temperature (°C) |
| TAB | = | Average temperature along AB (°C) |
| Tm | = | Melting temperature of the work material (°C) |
| tu, tc | = | Uncut and deformed chip thickness (mm) |
| V, VS,VC | = | Cutting velocity, shear velocity, and chip velocity (m/s) |
| w | = | Width of cut (mm) |
| α | = | Tool rake angle (degrees) |
| εAB | = | Effective strain at AB |
| έ0 | = | Reference strain rate (s −1) |
| Φ | = | Shear angle (degrees) |
| μ | = | Coefficient of friction in the elastic contact region |
| σAB | = | Effective flow stress at AB (N/mm2) |
| γ | = | Relief Angle (degrees) |
| λ | = | Friction Angle (degrees) |