Research on the influence of tool geometric parameters on the LSEM mechanism of 7A04 aluminum alloy

In order to explore the influence of tool geometric parameters on the large-strain extrusion machining (LSEM) mechanism of 7A04 aluminum alloy, based on the Abaqus finite element (FE) analysis software, the LSEM process of 7A04 aluminum alloy is simulated, with focus on how equivalent stress, equivalent strain, cutting temperature and cutting force change with tool geometric parameters. The results show that as cutting tool rake angle increases, equivalent stress first decreases then increases; equivalent strain first increases then decreases and then increases again; cutting temperature first decreases then increases; cutting force first decreases then increases. As constraining tool corner radius increases, equivalent stress first increases then decreases; equivalent strain, cutting temperature and cutting force are all positively correlated with constraining tool corner radius. Adding micro-textures can effectively increase the equivalent strain generated by LSEM and reduce the cutting force generated by LSEM. If a smaller cutting force were considered an indicator of a better tool geometric parameter, then alpha = 15 degrees, R = 0, and adding rectangular-sectioned strip texture only on the constraining tool should be the best option.