2D FEM simulation and experimental verification of Al 7075‐T6 during turning process

In this work, temperature distribution, effective stress and strain distribution in Al 7075‐T6 material and plastic flow of materials during turning process have been studied using Deform 3D v11.0 software. The four different points (P1, P2, P3, and P4) were chosen at the different locations in the cylindrical workpiece and the graph has been plotted with different parameters namely, temperature distribution, effective stress and strain. For temperature distribution, a good agreement has been found between simulation and experimental results at P4. The following results obtained from the simulation: In tertiary zone, the maximum temperature of specimen reaches upto 142 °C at points P1 due to friction between the tool rack face and the lower surface of chip. Maximum effective stress value reaches upto 650 MPa and 704 MPa at P1 and P4 respectively in the first sticking zone due to the combined effect of high normal force by tool edge and ploughing force. The effective strain value at P1 and P4 obtained, strain at P4 reaches maximum compare to P1 due to friction and unven temperature distribution. Additionally, chip analysis has been performed with microscopic image. The main aims of this paper are temperature distribution, effective stress and strain distribution in Al 7075‐T6 material. The plastic flow of materials during turning process has been studied using DEFORM 3D v11.0 software. The temperature distribution is compared with experimental results. A good agreement has been found between simulation and experimental results at P4.