Predictive Analytical and Thermal Modeling of Orthogonal Cutting Process—Part I: Predictions of Tool Forces, Stresses, and Temperature Distributions

2005 ◽  
Vol 128 (2) ◽  
pp. 435-444 ◽  
Author(s):  
Yiğit Karpat ◽  
Tuğrul Özel
Keyword(s):  
Shear Zone ◽  
Thermal Modeling ◽  
Orthogonal Cutting ◽  
Cutting Process ◽  
Field Analysis ◽  
Normal Stress Distribution ◽  
Modeling Approach ◽  
Temperature Distributions ◽  
Secondary Shear Zone ◽  
1045 Steel

In this paper, a predictive thermal and analytical modeling approach for orthogonal cutting process is introduced to conveniently calculate forces, stress, and temperature distributions. The modeling approach is based on the work material constitutive model, which depends on strain, strain rate, and temperature. In thermal modeling, oblique moving band heat source theory is utilized and analytically combined with modified Oxley’s parallel shear zone theory. Normal stress distribution on the tool rake face is modeled as nonuniform with a power-law relationship. Hence, nonuniform heat intensity at the tool-chip interface is obtained from the predicted stress distributions utilizing slip line field analysis of the modified secondary shear zone. Heat sources from shearing in the primary zone and friction at the tool-chip interface are combined, heat partition ratios are determined for temperature equilibrium to obtain temperature distributions depending on cutting conditions. Model validation is performed by comparing some experimental results with the predictions for machining of AISI 1045 steel, AL 6082-T6, and AL 6061-T6 aluminum. Close agreements with the experiments are observed. A set of detailed, analytically computed stress and temperature distributions is presented.

Influence of Reground Tool Sharpness on Micro-Cutting Process

2010 ◽  
Vol 37-38 ◽  
pp. 550-553
Author(s):  
Xin Li Tian ◽  
Zhao Li ◽  
Xiu Jian Tang ◽  
Fang Guo ◽  
Ai Bing Yu
Keyword(s):  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
Chip Thickness ◽  
Cutting Edge ◽  
Cutting Process ◽  
Micro Cutting ◽  
Temperature Distributions ◽  
Edge Radius ◽  
1045 Steel

Tool edge radius has obvious influences on micro-cutting process. It considers the ratio of the cutting edge radius and the uncut chip thickness as the relative tool sharpness (RST). FEM simulations of orthogonal cutting processes were studied with dynamics explicit ALE method. AISI 1045 steel was chosen for workpiece, and cemented carbide was chosen for cutting tool. Sixteen cutting edges with different RTS values were chosen for analysis. Cutting forces and temperature distributions were calculated for carbide cutting tools with these RTS values. Cutting edge with a small RTS obtains large cutting forces. Ploughing force tend to sharply increase when the RTS of the cutting edge is small. Cutting edge with a reasonable RTS reduces the heat generation and presents reasonable temperature distributions, which is beneficial to cutting life. The force and temperature distributions demonstrate that there is a reasonable RTS range for the cutting edge.

Predictive Analytical and Thermal Modeling of Orthogonal Cutting Process—Part II: Effect of Tool Flank Wear on Tool Forces, Stresses, and Temperature Distributions

2005 ◽  
Vol 128 (2) ◽  
pp. 445-453 ◽  
Author(s):  
Yiğit Karpat ◽  
Tuğrul Özel
Keyword(s):  
Flank Wear ◽  
Thermal Modeling ◽  
Orthogonal Cutting ◽  
Force Model ◽  
Stress Distributions ◽  
Tool Flank Wear ◽  
Temperature Distributions ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

In this paper, predictive modeling of cutting and ploughing forces, stress distributions on tool faces, and temperature distributions in the presence of tool flank wear are presented. The analytical and thermal modeling of orthogonal cutting that is introduced in Part I of the paper is extended for worn tool case in order to study the effect of flank wear on the predictions. Work material constitutive model based formulations of tool forces and stress distributions at tool rake and worn flank faces are utilized in calculating nonuniform heat intensities and heat partition ratios induced by shearing, tool-chip interface friction, and tool flank face-workpiece interface contacts. In order to model forces and stress distributions under the flank wear zone, a force model from Waldorf (1996) (“Shearing Ploughing, and Wear in Orthogonal Machining,” Ph.D. thesis, University of Illinois at Urbana-Champaign, IL) is adapted. Model is tested and validated for temperature and force predictions in machining of AISI 1045 steel and AL 6061-T6 aluminum.

Cutting Process Analysis for Uniform and Variable Edge Tools

2010 ◽  
Vol 37-38 ◽  
pp. 280-283
Author(s):  
Zhao Li ◽  
Ai Bing Yu ◽  
Hao Wang ◽  
Liang Dong
Keyword(s):  
Cutting Forces ◽  
Cutting Tool ◽  
Process Analysis ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
Cutting Process ◽  
Fem Modeling ◽  
Temperature Distributions ◽  
Aisi 1045 Steel ◽  
1045 Steel

Tool edge geometry has obvious influences on cutting tool behaviors. FEM modeling and simulation of orthogonal cutting process using uniform and variable edge cutting tools were studied with dynamics explicit ALE method. AISI 1045 steel was chosen for workpiece, and cemented carbide was chosen for cutting tool. Three sections of uniform and variable edges were chosen for analysis. Cutting forces and temperature distributions were calculated for uniform and variable edge carbide cutting tool. Simulation results show that variable edge cutting tool obtains small cutting forces. Ploughing force tends to reduce when variable edge cutting tool was used. Variable edge cutting tool reduces the heat generation and presents reasonable temperature distributions, which is beneficial to cutting life. The force and temperature distributions demonstrate the advantages of variable edge cutting tool.

Effect of Minimum Quantity Lubrication to Prediction of Cutting Temperature Distribution in Turning Material AISI-1045

2020 ◽  
Vol 902 ◽  
pp. 97-102
Author(s):  
Tran Trong Quyet ◽  
Pham Tuan Nghia ◽  
Nguyen Thanh Toan ◽  
Tran Duc Trong ◽  
Luong Hong Sam ◽  
...  
Keyword(s):  
Temperature Distribution ◽  
Shear Zone ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Chip Thickness ◽  
Minimum Quantity Lubrication ◽  
Minimum Quantity ◽  
The Difference ◽  
Secondary Shear Zone ◽  
Cutting Model

This paper presents a prediction of cutting temperature in turning process, using a continuous cutting model of Johnson-Cook (J-C). An method to predict the temperature distribution in orthogonal cutting is based on the constituent model of various material and the mechanics of their cutting process. In this method, the average temperature at the primary shear zone (PSZ) and the secondary shear zone (SSZ) were determined for various materials, based on a constitutive model and a chip-formation model using measurements of cutting force and chip thicknes. The J-C model constants were taken from Hopkinson pressure bar tests. Cutting conditions, cutting forces and chip thickness were used to predict shear stress. Experimental cutting heat results with the same cutting parameters using the minimum lubrication method (MQL) were recorded through the Testo-871 thermal camera. The thermal distribution results between the two methods has a difference in value, as well as distribution. From the difference, we have analyzed some of the causes, finding the effect of the minimum quantity lubrication parameters on the difference.

Prelimenary Study on Thermomechanical Modelling of Cutting Process

2011 ◽  
Vol 383-390 ◽  
pp. 6741-6746
Author(s):  
Wan Masrurah Bt Hairudin ◽  
Mokhtar B. Awang
Keyword(s):  
Maximum Stress ◽  
Orthogonal Cutting ◽  
Cutting Process ◽  
Maximum Temperature ◽  
Arbitrary Lagrangian Eulerian ◽  
Element Analysis ◽  
Ale Formulation ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

In this paper, thermo mechanical modelling of cutting process has been developed using a commercially available finite element analysis software, ABAQUS. A 2-D orthogonal cutting has been modelled using Arbitrary Lagrangian-Eulerian (ALE) formulation. The Johnson-Cook plasticity model has been assumed to describe the material behaviour during the process. This study is aimed at temperature and stresses distributions during machining of AISI 1045 steel with different rake angles; α=0° and α= -10°. The results showed that the maximum stress for 0° and -10° are 963MPa and 967MPa while the maximum temperature results shown that 771°C and 347°C.

Analytical and Thermal Modeling of High-Speed Machining With Chamfered Tools

2007 ◽  
Vol 130 (1) ◽  
Author(s):  
Yiğit Karpat ◽  
Tuğrul Özel
Keyword(s):  
Heat Generation ◽  
High Speed ◽  
Thermal Modeling ◽  
Orthogonal Cutting ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
High Speed Machining ◽  
Temperature Distributions ◽  
Dead Metal Zone ◽  
Chamfered Tools

High-speed machining offers several advantages such as increased flexibility and productivity for discrete-part manufacturing. However, excessive heat generation and resulting high temperatures on the tool and workpiece surfaces in high-speed machining leads to a shorter tool life and poor part quality, especially if the tool edge geometry and cutting conditions were not selected properly. In this study, analytical and thermal modeling of high-speed machining with chamfered tools in the presence of dead metal zone has been presented to investigate the effects of cutting conditions, heat generation, and resultant temperature distributions at the tool and in the workpiece. An analytical slip-line field model is utilized to investigate the process mechanics and friction at the tool-chip and tool-workpiece interfaces in the presence of the dead metal zone in machining with a negative rake chamfered polycrystalline cubic boron nitride tool. In order to identify friction conditions, a set of orthogonal cutting tests is performed on AISI 4340 steel and chip geometries and cutting forces are measured. Thermal modeling of machining with chamfered tools based on moving band heat source theory, which utilizes the identified friction conditions and stress distributions on the tool-chip and tool-workpiece interfaces, is also formulated and temperature distributions at the tool, cutting zone, and in the workpiece are obtained. These temperature distributions are compared with the results obtained from finite element simulations. The comparison of temperature fields indicates that the proposed model provides reasonable solutions to understand the mechanics of machining with chamfered tools. Models presented here can be further utilized to optimize the tool geometry and cutting conditions for increasing benefits that high-speed machining offers.

Identification of Material Constitutive Laws for Machining—Part II: Generation of the Constitutive Data and Validation of the Constitutive Law

2010 ◽  
Vol 132 (5) ◽  
Author(s):  
Bin Shi ◽  
Helmi Attia ◽  
Nejah Tounsi
Keyword(s):  
Shear Zone ◽  
High Speed ◽  
Split Hopkinson Pressure Bar ◽  
Orthogonal Cutting ◽  
Material Behavior ◽  
Constitutive Law ◽  
Primary Zone ◽  
Wide Range ◽  
Static Conditions ◽  
Secondary Shear Zone

This paper presents an integral methodology to obtain a wide range of constitutive data required for the identification of the constitutive equation used in simulating cutting processes. This methodology is based on combining the distributed primary zone deformation (DPZD) model developed in Part I (Shi et al., 2010, ASME J. Manuf. Sci. Eng., 132, p. 051008.) of this study with quasi-static indentation (QSI) tests, orthogonal cutting tests at room temperature (RT) and high temperature. The QSI tests are used to capture the material properties in the quasi-static conditions, which solve the unstable solutions for the coefficients of the constitutive law. The RT cutting tests are designed to fulfill the assumptions embedded in the developed DPZD model in order to provide the distributed constitutive data encountered in the primary shear zone. To capture the material behavior in the secondary shear zone, the orthogonal cutting tests with a laser preheating system are designed to raise the temperature in the primary zone to the level encountered in the secondary zone. As an application of the generated constitutive data, the Johnson–Cook model is identified for Inconel 718. This constitutive law is further validated using high speed split Hopkinson pressure bar tests and orthogonal cutting tests combined with finite element simulations. In comparison with the previous approaches reported in the open literature, the developed DPZD model and methodology significantly improve the accuracy of the simulation results.

Specification of Shear Zone Characteristics in Achieving Desired Residual Stress Profile

2007 ◽  
Author(s):  
Carl R. Hanna ◽  
Steven Y. Liang ◽  
Ru-Min Chao
Keyword(s):  
Residual Stress ◽  
Shear Zone ◽  
Orthogonal Cutting ◽  
Cutting Process ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Stress Profile ◽  
Residual Stress Profile ◽  
Design And Optimization ◽  
Machined Residual Stress

Surface integrity of a machined component in meeting the demands of a specific application requirement is defined by several characteristics. The residual stress profile at the surface and sub-surface of the workpiece is often one of these characteristics as it carries a direct effect on the fatigue life of a machined component. Machined residual stress is difficult to predict since it is governed by less than predictable high stresses, temperature gradients, and phase transformation occurring during the cutting process. A significant amount of effort have been dedicated by researchers to predict residual stress in a workpiece using analytical, experimental, and numerical modeling methods. Nonetheless, no method is available that could express the cutting process parameters and tool geometry parameters as functions of machined residual stress profile to allow process planning in achieving desired residual stress profile. This paper presents a physics-based approach to predict the shear zone characteristics during an orthogonal cutting operation. Using machined residual stress requirement at the surface as an input, information such as the shear angle, the shear stress in the shear zone, the depth of cut and consequently the cutting forces are obtained by inverse calculations procedure based on the rolling/sliding contact theory, the McDowell hybrid residual stress algorithm, and the specific cutting energy. This work constitutes a basis for further design and optimization of process and tool geometry parameters in achieving a specified residual stress profile. Experimental data are presented to validate the developed model.

Methodology for the Measurement of the Heat Partitioning by Thermal Imaging in the Orthogonal Cutting Process

2019 ◽  
Vol 141 (7) ◽  
Author(s):  
T. Augspurger ◽  
T. Bergs ◽  
B. Döbbeler ◽  
A. Lima
Keyword(s):  
Process Parameters ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Thermal Conditions ◽  
Heat Fluxes ◽  
Cutting Process ◽  
Major Influence ◽  
Work Piece ◽  
Essential Question ◽  
Secondary Shear Zone

The thermal conditions like temperature distribution and heat fluxes during metal cutting have a major influence on the machinability, the tool life time, and the metallurgical structure of the work piece material. Though numerous analytical and experimental efforts have been developed in order to understand the thermal conditions in metal cutting, many questions still prevail. So, the exact form, distribution, and intensity of heat sources in the primary and secondary shear zone, which may describe the observed temperature distributions, are not explored to a satisfactory extend. On the other hand, the influence of the material properties like friction coefficient, heat conductivity, and shear strength is not yet fully understood. Another essential question is the heat flux partition among chip, work piece, and tool depending on process parameters and material. The particular novelty of the current investigation is a new methodological approach using modern thermal measurement system and postprocessing methods in order not only to measure the entire temperature field in the orthogonal cutting zone but also to calculate the affiliated heat flow distribution in the cutting process. Thus, the cutting process is treated as energy conversation process of the governing mechanical power into sensible heat. This point of view offers compatibility across process parameters and materials, thus new possibilities for process design.

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