Finite element (FE) simulation is an efficient and time-saving method to optimize the high-speed machining process of aluminum (Al) alloy. The constitutive model accurately described the dynamic mechanical behavior of materials at cutting conditions is the premise of obtaining high-precision simulation results. In this study, the flow stress-strain relationship of AA 6061-T6 is obtained at a high temperature (up to 400 °C) and a high strain rate (up to 1 × 10⁴ s⁻¹). Temperature-dependent Johnson-Cook (J-C) model is proposed by considering dynamic recrystallization effect. By the modified J-C model, a two-dimensional simplified FE model is established to optimize the high-speed milling process of AA 6061-T6 hard drive head (HDH) access arm. The results show that the modified J-C constitutive model has a good prediction accuracy, and the predicted cutting forces are in good agreement with the experimental results. By the finite element simulations, the influences of both cutting parameters and tool geometric parameters on cutting force, chip morphology, cutting temperature, effective stress and effective strain are analyzed during cutting processes of AA 6061-T6. Optimized range of cutting parameters and tool geometric parameters are obtained, which provides a theoretical guidance for the optimization of the cutting processes of Al alloy precision parts.

有限元（FE）模拟是一种优化铝（Al）合金高速加工工艺的高效省时的方法。本构模型准确地描述了切削条件下材料的动态力学行为是获得高精度仿真结果的前提。在这项研究中，AA 6061-T6的流动应力-应变关系是在高温（最高400°C）和高应变速率（最高1×10 ⁴ s ^{-1）下获得的}）。通过考虑动态重结晶效应，提出了温度相关的约翰逊库克模型。通过修改后的JC模型，建立了二维简化的有限元模型，以优化AA 6061-T6硬盘驱动器头（HDH）存取臂的高速铣削过程。结果表明，改进后的JC本构模型具有良好的预测精度，预测的切削力与实验结果吻合良好。通过有限元模拟，分析了AA 6061-T6切削过程中切削参数和刀具几何参数对切削力，切屑形态，切削温度，有效应力和有效应变的影响。获得了最佳的切削参数范围和刀具几何参数，