Coupled Eulerian-Lagrangian (CEL) simulation for modelling of chip formation in AA2024-T3

Aluminium alloys are of the most used alloys in the aeronautic industry. Increasing knowledge in machining and prediction of chip formation in these materials is crucially important to design better components with enhanced functional performance. To achieve this, a new finite element modelling strategy is developed to incorporate material damage and softening in the Coupled Eulerian-Lagrangian (CEL) formulation for the machining of AA2024 alloy. The CEL modelling technique is adopted to simulate chip formation at high cutting speeds. An orthogonal cutting setup is used to compare the modelling predictions with experimentally measured cutting forces and chips sections. The proposed model shows a good ability to reproduce the experimental results and to predict the trends induced by variations in the cutting conditions.