Abstract
The understanding of physical parameters of machining processes of aerospace grade aluminium alloy is always of prime importance. The main concern is always to understand the chip formation process and the resultant cutting force experienced by the tool due to different parameters like cutting speeds, feed rate, friction coefficient and tool rake angle etc. The finite element analysis has replaced many expensive and time consuming physical machining processes. In the present work, an extensive study of different parameters affecting the turning process of aluminium alloy (A2024-T351) is performed using 2D finite element analysis. The Johnson-Cook ductile material model based on coupled plasticity and damage evolution is employed to simulate the cutting process. The authenticity of the performed simulation work is verified by comparing the simulation results with available experimental data on machining of aluminium alloy (A2024-T351).