NUMERICAL SIMULATION OF CONTINUOUS CHIP FORMATION DURING NON‐STEADY ORTHOGONAL CUTTING

1993 ◽  
Vol 10 (1) ◽  
pp. 31-48 ◽  
Author(s):  
G.S. SEKHON ◽  
J.L. CHENOT
Keyword(s):  
Numerical Simulation ◽  
Chip Formation ◽  
Orthogonal Cutting ◽  
Continuous Chip

An Analysis of the Mechanism of Orthogonal Cutting and Its Application to Discontinuous Chip Formation

1961 ◽  
Vol 83 (4) ◽  
pp. 545-555 ◽  
Author(s):  
Keiji Okushima ◽  
Katsundo Hitomi
Keyword(s):  
Chip Formation ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Plastic Region ◽  
Flow Region ◽  
Shear Plane ◽  
Experimental Result ◽  
Conventional Theory ◽  
Boundary Lines ◽  
Continuous Chip

Instead of the conventional theory of the mechanics of metal cutting based on a process of shear confined to a single shear plane, the concept of flow region, a fairly large transitional deformation zone which exists between the rigid region of work and the plastic region of steady chip, was developed. The mechanics of orthogonal cutting was analyzed, theoretical equations for angles of boundary lines of the flow region and for strain in chip were deduced in the case of simple continuous chip formation and confirmed in cutting tests on lead. The concept of flow region was also applied to discontinuous chip formation, and theoretical expressions for angles of boundary lines of the flow region were ascertained to be in agreement with the experimental result for carbon steel.

On Methodologies inside Two Different Commercial Codes to Simulate the Cutting Operation

2011 ◽  
Vol 223 ◽  
pp. 162-171
Author(s):  
Yan Cheng Zhang ◽  
Domenico Umbrello ◽  
Tarek Mabrouki ◽  
Stefania Rizzuti ◽  
Daniel Nelias ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Titanium Alloy ◽  
Surface Integrity ◽  
Chip Formation ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Cutting Parameters ◽  
Cutting Operation ◽  
Cutting Processes ◽  
Cutting Model

Nowadays, numerical simulation of cutting processes receives considerable interest among the scientific and industrial communities. For that, various numerical codes are used. Nevertheless, there is no uniform standard for the comparison of simulation model with these different software. So, it is often not easy to state if a given code is more pertinent than another. In this framework, the present work deals with various methodologies to simulate orthogonal cutting operation inside two commercial codes Abaqus and Deform. The aim of the present paper is to build a common benchmark model between the two pre-cited codes which can initiate other numerical cutting model comparisons. The study is focused on the typical aeronautical material - Ti-6Al-4V - Titanium alloy. In order to carry out a comparative study between the two codes, some similar conditions concerning geometrical models and cutting parameters were respected. A multi-physic comprehension related to chip formation, cutting forces and temperature evolutions, and surface integrity is presented. Moreover, the numerical results are compared with experimental ones.

SPH Meshless Simulation of Orthogonal Cutting of AA6060-T6

2015 ◽  
Vol 808 ◽  
pp. 258-263 ◽  
Author(s):  
Julean Dănuț
Keyword(s):  
Numerical Simulation ◽  
Experimental Research ◽  
Convenient Method ◽  
Formation Process ◽  
Chip Formation ◽  
Meshless Method ◽  
Orthogonal Cutting ◽  
Smooth Particle Hydrodynamics ◽  
Simulation Data ◽  
Particle Hydrodynamics

A modern meshless method known as Smooth Particle Hydrodynamics (SPH) was involved in achieving numerical simulation of chip formatting during the orthogonal cutting of AA6060-T6 alloy with the aim of finding a convenient method for investigating the chip formation and reducing the costs of experimental research by involving numerical simulation in order to get information about the parameters describing the process. Based on a few experimental orthogonal cutting results the procedure to achieve a proper numerical simulation of the chip formation process is presented. The procedure and the results may be applied when simulation data and prognosis data about machining AA6060-T6 data are needed.

Modeling and numerical simulation of the chip formation process when machining Nomex

2021 ◽  
Author(s):  
Tarik Zarrouk ◽  
Jamal-Eddine Salhi ◽  
Samir Atlati ◽  
Mohammed Nouari ◽  
Merzouki Salhi ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Formation Process ◽  
Chip Formation

Investigation on the Elemental Chip Formation Process in Hard-to-Machine Material Cutting

2014 ◽  
Vol 682 ◽  
pp. 504-509 ◽  
Author(s):  
A.A. Lasukov ◽  
P.A. Chazov ◽  
А.V. Barsuk
Keyword(s):  
Mechanical Properties ◽  
Formation Process ◽  
Chip Formation ◽  
Physical And Mechanical Properties ◽  
Cutting Process ◽  
Machine Material ◽  
Continuous Chip ◽  
Material Cutting

The mechanism of discontinuous chip formation has been studied less than the mechanism of continuous chip formation. However, when most modern materials having specific physical and mechanical properties are subject to machining, such processes are featured by discontinuous chip formation. The paper describes the basic dependencies of discontinuous chip parameters on machining modes. This is a trial undertaken to introduce an explanation of how the basic factors of the cutting process influence over parameters of chip formation.

Finite Element and Experimental Analysis of Edge Defects Formation during Orthogonal Cutting of SiCp/Al Composites

2012 ◽  
Vol 500 ◽  
pp. 146-151 ◽  
Author(s):  
Ning Hou ◽  
Li Zhou ◽  
Shu Tao Huang ◽  
Li Fu Xu
Keyword(s):  
Finite Element ◽  
Chip Formation ◽  
Defect Formation ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Rake Angle ◽  
Critical Transition ◽  
Cutting Depth ◽  
Edge Defect ◽  
Edge Defects

In this paper, a finite element method was used to dynamically simulate the process of the edge defects formation during orthogonal cutting SiCp/Al composites. The influence of the cutting speed, cutting depth and rake angle of the PCD insert on the size of the edge defects have been investigated by using scanning electron. According to the simulated results, it can be provided that the cutting layer material has an effect on transfer stress and hinder the chip formation in the critical transition stage, and the critical transition point and distance are defined in this stage. The negative shear phenomenon is found when the chip transit to the edge defects in the flexure deformation stage, so the process of the chip formation is the basis of the edge defects formation. In addition, the relationship between the nucleation and propagation direction of the crack and the variation of the edge defect shape on the workpiece was investigated by theory, and it found that the negative shear angle formation is the primary cause of the edge defect formation. A mixed mode crack is found in the crack propagation stage. The sizes of edge defects were measured by the experiment and simulation, and the edge defect size decrease with the increasing of tool rake angle, while increase with increasing cutting depth and cutting speed.

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