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Because of the massive work and high cost of milling experiments, finite element analysis technology (FEA) was used to analyze the milling process of ADC12 aluminum alloy. An improved Johnson–Cook (J–C) constitutive equation was fitted by a series of dynamic impact tests in different strain rates and temperatures. It found that the flow stress gradually increases as the strain rate rises, but it decreases as the test temperature rises. Compared with the J–C constitutive model, the predicted flow stress by the improved J–C constitutive model was closer to the experimental results when the strain rate was larger than 8000 s−1 and the temperature was higher than 300 °C. A two-dimensional cycloidal cutting simulation model was constructed based on the two J–C constitutive equations which was validated by milling experiments at different cutting speeds. The simulation results based on the improved J–C constitutive equation were closer to the experimental results and showed the cutting force first increased and then decreased, with cutting speed increasing, reaching a maximum at 600 m/min.

An Improved Johnson–Cook Constitutive Model and Its Experiment Validation on Cutting Force of ADC12 Aluminum Alloy During High-Speed Milling