Numerical simulation and experimental investigations on high-speed cutting driven by electromagnetic forces

Electromagnetic impact cutting was proposed in this work and corresponding experiments under different cutting thickness were conducted using 7075-T6 aluminum alloy plates. A numerical simulation model for electromagnetic impact cutting was established to obtain cutting forces and stress-strain evolution. The linear height and surface roughness of machined surfaces to characterize the machined quality of these surfaces. The results showed that cutting displacement gradually decreased as the cutting thickness increased, while the cutting force increased accordingly. The stress concentration zone in electromagnetic impact cutting was located in the initial deformation zone, and the stress decreased steadily as it moved away from the cutting layer area. In addition, the maximum equivalent plastic strain exhibited a gradual decreasing trend with the increase in cutting thickness. The relationship between surface roughness and sample thickness was not monotonic. It reached a peak when the thickness was 0.8 mm. Both numerical simulations and experimental studies revealed that the electromagnetic impact cutting method was reliable and could be using explore high-speed cutting mechanism.