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www.elsevier.com/locate/procedia
Procedia Manufacturing 43 (2020) 471–478

17th
17th Global
Global Conference
Conference on
on Sustainable
Sustainable Manufacturing
Manufacturing

Finite
Finite element
element modeling
modeling of
of high-speed
high-speed milling
milling 7050-T7451
7050-T7451 alloys
alloys
Xianghui
Xianghui Huang
Huanga,, Jinyang
a
Jinyang Xu
Xua,, Ming
a
Ming Chen
Chena*,
a
*, Fei
Fei Ren
Renb
b

aStateKey Laboratory of Mechanical System and Vibration, School of Mechanical Engineering Shanghai Jiao Tong University, Shanghai 200240,
a
State Key Laboratory of Mechanical System and Vibration, School of Mechanical Engineering Shanghai Jiao Tong University, Shanghai 200240,
PR China
PR China
bShanghai Aerospace Equipments Manufacturer Co., Ltd., Shanghai 200245, PR China
b
Shanghai Aerospace Equipments Manufacturer Co., Ltd., Shanghai 200245, PR China

Abstract
Abstract
In
In this
this paper,
paper, high-speed
high-speed milling
milling aluminum
aluminum alloy
alloy 7050-T7451
7050-T7451 was was studied
studied using
using finite
finite element
element simulation.
simulation. First,
First, based
based onon two-
two-
dimensional
dimensional orthogonal cutting model, the influence of the cutting speed on the cutting force was studied in the process of
orthogonal cutting model, the influence of the cutting speed on the cutting force was studied in the process of
machining.
machining. The
The results
results shown
shown that
that with
with the
the increase
increase of
of cutting
cutting speed,
speed, the
the cutting
cutting force
force originally increased and
originally increased and then
then decreased.
decreased.
When the
When the feed
feed per
per tooth
tooth increased,
increased, the
the inflection
inflection point
point of
of cutting
cutting speed
speed would
would increase. Besides, when
increase. Besides, when the
the cutting
cutting speed
speed was
was
larger
larger than 4000m/min, the cutting temperature decreased. By three-factor and three-level simulation schemes, the influence of
than 4000m/min, the cutting temperature decreased. By three-factor and three-level simulation schemes, the influence of
tool
tool rake
rake angle,
angle, relief
relief angle
angle and
and feed
feed per
per tooth
tooth on
on cutting
cutting force
force were
were analyzed.
analyzed. According
According to to three-dimensional
three-dimensional cutting
cutting model,
model, the
the
effect
effect of
of cutting
cutting edge
edge inclination
inclination angle
angle on
on cutting
cutting force was researched.
force was researched. Last,
Last, the
the cutting
cutting forces
forces ofof simulation
simulation were
were compared
compared
against the
against the experimental
experimental results.
results. The
The maximum cutting force
maximum cutting force error
error was
was 10.4%.
10.4%. According
According to to the
the law
law of
of simulation,
simulation, the
the number
number ofof
experiments
experiments isis reduced
reduced inin the
the process
process ofof optimizing
optimizing the
the cutting
cutting parameters.
parameters.
© 2019
© 2020 The
The Authors.
Authors, Published
Published by
by Elsevier B.V.
© 2019
This The
is an Authors,
open accessPublished by Elsevier
article under Elsevier B.V.
B.V.
the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer review
Peer review under
review under the
underthe responsibility
responsibilityofof
theresponsibility the
ofthe scientific
thescientific
scientific committee
committee of
of the
the Global
Global Conference
Conference on
on Sustainable
Sustainable Manufacturing
Manufacturing
committee of the Global Conference on Sustainable Manufacturing.
Keywords: Type your keywords here, separated by semicolons ;
Keywords: Type your keywords here, separated by semicolons ;

1.
1. Introduction
Introduction
Aluminum
Aluminum alloy
alloy is
is widely
widely used
used inin train
train and
and aviation
aviation aircraft
aircraft manufacturing
manufacturing because
because of of its
its high
high specific
specific strength,
strength,
low
low cost and easy processing. In aluminum alloy process, high-speed milling has become an
cost and easy processing. In aluminum alloy process, high-speed milling has become an advanced
advanced
manufacturing technology with
manufacturing technology with high
high efficiency
efficiency and
and low
low energy
energy consumption
consumption after
after long-term
long-term development
development [1].
[1].
However, the problems of weak rigidity and deformation cannot be ignored for high-precision structural
However, the problems of weak rigidity and deformation cannot be ignored for high-precision structural components. components.
The cutting
The cutting force,
force, cutting
cutting temperature
temperature and and stress
stress distribution
distribution during
during high-speed
high-speed cutting
cutting process
process areare important
important factors
factors
leading to machining deformation, and had been widely studied to optimize the machining
leading to machining deformation, and had been widely studied to optimize the machining results. With the results. With the
continuous improvement of numerical simulation software and the computational power
continuous improvement of numerical simulation software and the computational power of computer, low-cost, of computer, low-cost,
high-efficiency and
high-efficiency and pollution-free
pollution-free simulation
simulation analysis
analysis has
has become
become aa very
very important
important wayway in in the
the process
process ofof
optimization. Karinna M et al. studied the surface temperature of workpiece at high-speed
optimization. Karinna M et al. studied the surface temperature of workpiece at high-speed cutting aerospace cutting aerospace

2351-9789 © 2019 The Authors, Published by Elsevier B.V.

2351-9789 © 2019 The Authors, Published by Elsevier B.V.
Peer review under the responsibility of the scientific committee of the Global Conference on Sustainable Manufacturing
Peer review under the responsibility of the scientific committee of the Global Conference on Sustainable Manufacturing

2351-9789 © 2020 The Authors. Published by Elsevier B.V.

This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)
Peer review under the responsibility of the scientific committee of the Global Conference on Sustainable Manufacturing.
10.1016/j.promfg.2020.02.186
472 Xianghui Huang et al. / Procedia Manufacturing 43 (2020) 471–478
2 Author name / Procedia Manufacturing 00 (2019) 000–000

aluminum alloys [2]. N. Fang proposed a sliding line model to predict the cutting force in aluminum alloy machining
[3]. Özel studied chip formation using dynamic re-mesh technology [4]. Sui XL built a ball-end milling cutter model
to simulate and verify the milling force for high-speed milling of aluminum alloy A2024 [5]. Wang F studied the
relationship between cutting edge radius and cutting force through micro milling model[6]. Perez I studied the
influence of cutting speed on surface integrity[7]. 7050-T7451 is an important material in aeronautical manufacture.
Feng J studies the relationship between cutting force and feed during turning of 7050-T7451 by modified power law
model[8]. While the relationship between cutting force, cutting temperature and cutting speed have not been deeply
studied. In this paper, we established simulation model by ABAQUS for high-speed milling aluminum alloy 7050-
T7451. The influence of cutting speed, cutting edge inclination angle, tool rake angle, tool relief angle and feed per
tooth on cutting force were studied, providing data reference for machining process optimization and tool design,
which reduce the number of test and the consumption of materials and energy. So it is beneficial to sustainable
manufacturing.

2. Finite element modeling

2.1. Material Model

Metal cutting is a comprehensive process of various mechanics. When using numerical simulation technology to
study the force, heat and chip changes in the cutting process, accurately defining the constitutive equation of the
material is the key to the high precision of the simulation. At present, the J-C constitutive model is the most
commonly used, its expression is as following [9,10].

 

 T  Tr m 
 =  A  B  1  C ln   1  (
n
)  (1)
 
0   Tm  Tr 

where  is the material strain,  is the strain rate,  is the reference strain rate,  are the material cutting
temperature, material melting point and room temperature. In addition, n is the strain hardening index, m is the
thermal softening index. the material property parameters of A, B, C, n, and m are obtained though experiment
respectively [11].In the finite element simulation, the physical criterion was chosen to define damage [12]. When the
element meets the condition, it failed. The equivalent strain was used as the physical separation criterion.
 p
D=  f
(2)
 p

f
where  p is the equivalent plastic strain of the element integration point, p is the critical equivalent plastic
f
strain. The value of p is calculated by Johnson-Cook failure criterion[13], The equivalent fracture strain defined
by the J-C model is:
    
 T  Tr m 
= d1 +d 2exp  d3   1+d 4 ln     1+d5 (
f
 p 
) 
    Tm  Tr 
 
 0 
(3)
In the formula (3),  = /  ,  is the yield stress,  is the yield stress at the reference strain rate, The
 m m

specific values of 7050-T7451 are shown in Table 1.

Table 1. Johnson-Cook constitutive parameter and failure model parameters of 7050-T7451 [11,14].
A [MPa] B [MPa] C n m Tm [℃] Tr [℃] d1 d2 d3 d4 d5
391 684 0.00959 0.436 2 620 20 0.71 1.248 -1.42 0.147 0
 Xianghui Huang et al. / Procedia Manufacturing 43 (2020) 471–478 473
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2.2. Geometric model

Orthogonal cutting describes the process of the cutting edge perpendicular to the cutting speed. Because its
calculation of the model was small, a series of levels of cutting speed was set to research the effects on cutting force.
A simple three-dimensional model is oblique cutting. It was the situation that the cutting edge is not
perpendicular to the cutting speed, which reflected more accurately the milling process. The tool cutting edge
inclination angle is equivalent to the helix angle in milling. In the three-dimensional oblique cutting model, the
cutting depth is different at different points of the cutting edge for the milling process. During the cutting process,
the trajectory of any point on the cutting edge is a spiral, which can be replaced by a circular line. Then, using the
equal-area method converts the variable cutting depth into the equivalent cutting depth to simulate the milling
process [15]. The equivalent cutting depth expression was shown in equation (4).

 f    f 
cos1  z   sin  2cos1  z  
A  2r    2r   (4)
hc  r  r 2  2 c  r  r
Kc  f 
  cos1  z 
 2r 

2.3. Cutting speed single factor simulation

The spindle speed of the domestic CNC center generally does not exceed 30000 r/min, if the common tool choose
diameter is 8 mm, the cutting speed is not more than 1000 m/min. The feed engagement of cutting edge in finishing
machining with hard alloy is 0.03~0.1 mm. The simulation scheme one is simulated in the speed range of 0~700
m/min, the cutting depth is 0.06mm. Although the rotation speed is high, the cutting speed is not very high because
the diameter is small. While, according to the Salomon theory, the inflection of cutting speed usually is
3000~4000m/min in the process of machining Aluminum [16]. So the simulation scheme two was to study higher
speed, the cutting depth was 0.3mm. The schemes were shown in the table 2. Tool rake angle, relief angle and blunt
round radius are 16 °, 12 °and 0.02 mm respectively.

Table 2 Cutting speed level (m/min).

Scheme 1 20 100 200 300 400 500 600 700
Scheme 2 180 360 720 1800 2400 3600 4200 4800

3. Orthogonal cutting analysis

3.1. Analysis of cutting force

The cutting depth is equal to the feed per tooth for milling process. High-speed milling is a process in which the
cutting depth changes periodically. When two-dimensional orthogonal cutting is used to simulate the milling process,
the result is equal to maximum cutting depth in milling process. The results were shown in the Fig.1
It can be seen from Fig. 1.a) that the cutting force has a tendency to decrease in volatility form, as the cutting
speed becomes larger. This was because that when the cutting speed becomes larger, the contact time between the
tool and the workpiece became shorter, the plastic flow of the metal was greater than the deformation speed, the
primary deformation zone moved backward, the shear angle increased, the degree of chip deformation and shear
strain energy reduces, and the increase of cutting temperature enhanced the thermal softening effect. So the cutting
force became small as a whole. There were two reasons for the protrusion at 600 m/min. One was the instability of
the simulation, the other might be the oscillation of the cutting process itself. For the obvious downward trend at 700
m/min, it is because thermal softening had an enhanced significant effect on this process.
As can be seen from the velocity load change in Fig.1 b), as the speed increases, the cutting force increased
originally and then decreased and finally stabilized. When the speed exceeds 3000 m/min, the cutting force
474 Xianghui Huang et al. / Procedia Manufacturing 43 (2020) 471–478
4 Author name / Procedia Manufacturing 00 (2019) 000–000

decreased obviously, and there was a proportional relationship. When the cutting speeding was greater than 4200
m/min, the cutting force tended to be gentle. Comparing the two schemes of simulation, the overall value of the
cutting force in the scheme two was large, indicating that the feed per tooth has a greater impact on the cutting force.
In addition, the initial speed in which the cutting force begin to decrease was also inconsistent. When the feed per
tooth was small, the speed turning point was relatively small. When the feed amount per tooth was large, a higher
cutting speed was required to occur cutting force decrease phenomenon.
a b

Fig. 1. The relation between cutting speed and cutting force. a) Scheme one; b) Scheme two

3.2. Cutting temperature analysis

As shown in the Fig.2. a), in the range of 0~700m/min, the temperature will increase with the increase of cutting
speed. In the Fig.2. b), the cutting temperature has a downward trend when the cutting speed is bigger than
4000m/min. The turning point is similar to Salomon theory.
Selecting the simulation whose cutting speed is 720 m/min to analysis, it can be seen from Fig. 6 that the
maximum temperature is 329 °C, the maximum temperature point is not at the tool nose, and the rake face is close to
the cutting edge. This is because the frictional heat increases along the rake surface. In the second half of the contact
between the rake face and the chip, the friction is gradually reduced (from internal friction to external friction), and
the heat is continuously transmitted, so the temperature gradient is large.

a b

Fig. 2. The relation between cutting speed and cutting temperature. a) Scheme one; b) Scheme two

3.3. Multi-factor simulation of rake angle, relief angle and cutting depth

According to the manual of high-speed milling, design three-factor three-level experiment as shown on the table
3 [17]. Ignoring the mutual interference between the three, assuming that the factors are independent of each other.
The results of nine simulations are shown in table 4. it can be clearly seen that the force in the horizontal direction is
greater than the force in the vertical direction. The specific influence law is visually analyzed using histogram, as
shown in fig.3. During the process of cutting aluminum alloy, the cutting force decreases with the increase of the
rake angle. This is because when the rake angle increases, the shear angle also increases, the metal plastic
 Xianghui Huang et al. / Procedia Manufacturing 43 (2020) 471–478 475
Author name / Procedia Manufacturing 00 (2019) 000–000 5

deformation reduces, then the deformation coefficient will decrease, and the frictional force along the rake face also
reduces, so the cutting force is lowered. Besides, the influence degree of the rake angle on the cutting force will
decreases as the cutting speed increases. This is because when the cutting speed is high, the cutting force increases
as the rake angle decreases, but increases at a lower speed. The degree of smallness is small because the cutting
temperature increases during high-speed cutting, and the friction, work hardening degree, and plastic deformation
are all reduced, and the sensitivity to the rake angle is also lowered. The cutting force increases with the increase of
the feed per tooth. This is because when the feed per tooth increases, the normal stress increases.

Table 3 The cutting force of simulation results

rake angle relief angle cutting depth
level 1 8° 8° 0.03 mm
level 2 12 ° 12 ° 0.06 mm
level 3 16 ° 16 ° 0.09 mm

Table 4 The cutting force of simulation results

F（N） Fx（N） Fy（N）

1（1111） 46.95 43.08 17.20

2（1222） 66.23 62.66 19.82
3（1333） 88.89 87.69 13.94
4（2123） 59.29 58.13 10.77
5（2231） 84.28 83.63 9.76
6（2312） 40.40 37.71 13.28
7（3132） 81.38 80.96 7.48
8（3213） 40.26 37.33 13.46
9（3321） 57.22 56.50 7.99

Fig.3 Bar graph of simulation results of orthogonal cutting

Through the analysis of the difference of the cutting force F, the three extreme values are obtained: 7.54, 1.42,
42.31, and the error term difference is 0.05. Three extreme values are obtained by analyzing the cutting force Fx
range: 6.22, 0.58, 44.72, Three extreme values are obtained for the analysis of the cutting force Fy: 7.34, 2.61, 4.25.
476 Xianghui Huang et al. / Procedia Manufacturing 43 (2020) 471–478
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So the cutting depth has the greatest influence on the cutting force, the rake angle has the second influence on the
cutting force, and the relief angle has the smallest influence on cutting force. Comparing the range difference with
the error term, the range of rake angle and the cutting depth are large, which means that the influence degree on the
cutting force is large, but the relief angle is close to error term, indicating that the relief angle has little effect on the
cutting force. The cutting force Fx has almost no effect.

4 Three-dimensional oblique cutting simulation

4.1 Simulation scheme

The cutting edge inclination angle in the oblique cutting is the helix angle of the milling cutter. The selection of
the helix angle is important for the cutting process. The large helix angle facilitates the discharge of the chip, but the
rigidity of the tool decreases. The small helix angle increases the rigidity of the tool, but it is not conducive to chip
discharge, and will be a large friction, which causes the cutting temperature increasing. Setting the cutting edge
inclination angle was 15 °, 30 °, 45 ° to simulation.
Cutting parameters: cutting speed 500 m/min; milling width: 4mm; milling depth: 0.3; tool diameter : 8 mm;
Bring the feed per tooth 0.06 mm into Equation (5) obtained an equivalent cut depth of 0.0382 mm. Tool parameters:
rake angle 16 °, relief angle 12 °. The wide of workpiece in the simulation is the contact length. When the cutting
edge inclination angle was 30 °, the contact length was 0.52mm.

4.2 Cutting force analysis

The simulation results are shown in the Fig.4. When the cutting edge inclination increases from 15 ° to 30 °, the
cutting force of Fx and Fz increases, and Fy decreases. When the cutting edge inclination increases from 30 ° to 45 °,
the cutting forces in all three directions are increased, the Fz direction’s increment is the biggest. That means, the
cutting force of Fx and Fz in the cutting plane increases as the cutting edge inclination increases, while the force
perpendicular to tool cutting edge plane does not change significantly. In high-speed milling process. On the one
hand, the selection of the helix angle requires little force. On the other hand, tool requires better chip removal
capability, and requires little radial force and good chip removal capability in side-milled aluminum alloys process.
The angle is preferably 30 °.

Fig.4. Cutting force with cutting edge inclination changes

4.3 Aluminum alloy experimental verification

 Xianghui Huang et al. / Procedia Manufacturing 43 (2020) 471–478 477
Author name / Procedia Manufacturing 00 (2019) 000–000 7

The milling processing experiment platform uses the JDCT1200E-A12E CNC machine tool. The cutting force
measuring device includes HBM data recorder, KISTLER series 5073 dynamometer, A/D converter of isdompre
WP10W-S-24. the principle diagram of the force measurement system is shown in Fig. 5.
The tool is a high-speed solid carbide end mill produced by Zigong Cemented Carbide Co. and the main
geometric parameters of Zigong solid carbide end mill are shown in Table 5. Combined with tool size and high-
speed milling parameter processing parameters, the 7050-T7451 aluminum alloy is machined into specimens of 5
mm ×12 mm× 10 mm.
The experiment results Fy = 28.1N and Fz = 10.6N. The plane XOZ of simulation corresponded to the plane
YOZ of the experiment. So the cutting force Fx of simulation should compare to the Fy of experiment. The
simulation results Fx and Fz were 25.2N, 10.5N, respectively. And the errors are 10.4% and 0.9% respectively.
The cutting force error in the Fy direction is large, but the error in the Fz direction is small. Analyze the reason,
there will be tool wear during the actual machining. While, the tool is a rigid body in the finite element analysis,
which results in the simulation data being small. As the cutting temperature increases during the cutting process, the
friction coefficient of the material was a variable, while the friction coefficient was constant during the simulation,
which also causes simulation errors. Simulation is a simplification of the model. It is difficult to completely
quantitative analyze the simulation results, but it is a very effective means to carry out the qualitative analysis.

Fig.5. Milling experiment system diagram

5 Conclusions

(1) Based on the two-dimensional orthogonal cutting model, we simulate the high-speed milling 7050-T7451. It
is found that with the cutting speed increase, the cutting force increases first and then decrease. And the turning
point is higher when the cutting depth is larger.
(2) Based on the orthogonal model, the three-factor and three-level factors of the rake angle, the relief angle and
the feed per tooth are analyzed through the method of range analysis. It is found that the feed per tooth has the
greatest influence on the cutting force, and the rake angle is the second and the relief angle is at the minimum, the
cutting force increases as the feed per tooth increases, and decreases as the rake angle increases.
(3) Based on the three-dimensional oblique cutting model, the cutting edge inclination angle’s effect on cutting
force is analyzed. The cutting force in the cutting plane increases with the increase of the cutting edge inclination
angle, and the force perpendicular to the cutting plane does not change significantly.

Acknowledgements

The work is sponsored by the National Science and Technology Major Project (Grant No. 2017ZX04005001).
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