Modified Primary Shear Zone Analysis for Identification of Material Mechanical Behavior During Machining Process Using Genetic Algorithm

2012 ◽  
Vol 134 (4) ◽  
Author(s):  
L. Pang ◽  
H. A. Kishawy
Keyword(s):  
Genetic Algorithm ◽  
Boundary Conditions ◽  
Strain Rate ◽  
Shear Strain ◽  
Shear Zone ◽  
Metal Cutting ◽  
Chip Thickness ◽  
Machining Process ◽  
Zone Model ◽  
Shear Strain Rate

In the current work, an inverse analysis on the primary shear zone was introduced to determine the five constants in Johnson–Cook’s material constitutive equation under the conditions of metal cutting. Based on the detailed analysis on the boundary conditions of the velocity and shear strain rate fields, Oxley’s “equidistant parallel-sided” shear zone model was revisited. A more realistic nonlinear shear strain rate distribution has been proposed under the frame of nonequidistant primary shear zone configuration, so that all the boundary conditions can be satisfied. Based on the presented analysis, the shear strain, shear strain rate and temperature at the main shear plane were calculated. In conjugation with the measured cutting forces and chip thickness, a genetic algorithm (GA) based optimization program has been developed for the system identification. In order to verify the effectiveness of the developed algorithm, the obtained material constants were used in a forward analytical simulation. The acceptable agreement with experimental data validates the proposed method.

scholarly journals Study of the Shear Strain and Shear Strain Rate Progression During Titanium Machining

2018 ◽  
Vol 140 (5) ◽  
Author(s):  
Brian Davis ◽  
David Dabrow ◽  
Peter Ifju ◽  
Guoxian Xiao ◽  
Steven Y. Liang ◽  
...  
Keyword(s):  
Strain Rate ◽  
Shear Strain ◽  
Chip Formation ◽  
Chip Morphology ◽  
Machining Process ◽  
Image Correlation ◽  
Shear Strain Rate ◽  
Rate Distribution ◽  
Continuous Chip ◽  
Strain Rate Distribution

Machining is among the most versatile material removal processes in the manufacturing industry. To better optimize the machining process, the knowledge of shear strains and shear strain rates within the primary shear zone (PSZ) during chip formation has been of great interest. The objective of this study is to study the strain and strain rate progression within the PSZ both in the chip flow direction and along the thickness direction during machining equal channel angular extrusion (ECAE) processed titanium (Ti). ECAE-processed ultrafine-grained Ti has been machined at cutting speeds of 0.1 and 0.5 m/s, and the shear strain and the shear strain rate have been determined using high speed imaging and digital image correlation (DIC). It is found that the chip morphology is saw-tooth at 0.1 m/s while continuous at 0.5 m/s. The cumulative shear strain and the incremental shear strain rate of the saw-tooth chip morphology can reach approximately 3.9 and 2.4 × 103 s−1, respectively, and those of the continuous chip morphology may be approximately 1.3 and 5.0 × 103 s−1, respectively. There is a distinct peak shift in the shear strain rate distribution during saw-tooth chip formation while there is a stable peak position of the strain rate distribution during continuous chip formation. The PSZ thickness during saw-tooth chip formation is more localized and smaller than that during continuous chip formation (28 versus 35 μm).

scholarly journals Crevasse initiation and history within the McMurdo Shear Zone, Antarctica

2019 ◽  
Vol 65 (254) ◽  
pp. 989-999 ◽  
Author(s):  
Lynn Kaluzienski ◽  
Peter Koons ◽  
Ellyn Enderlin ◽  
Gordon Hamilton ◽  
Zoe Courville ◽  
...  
Keyword(s):  
Strain Rate ◽  
Shear Strain ◽  
Shear Zone ◽  
Large Scale ◽  
Radar Data ◽  
Small Scale ◽  
Shear Strain Rate ◽  
Surface Shear ◽  
Study Region ◽  
In Situ Data

AbstractWhile large-scale observations of intensified fracture and rifting can be observed through remote-sensing observations, understanding crevasse initiation may best be achieved with small-scale observations in which crevasses can be directly observed. Here we investigate the kinematic drivers of crevasse initiation in the McMurdo Shear Zone (MSZ), Antarctica. We delineated 420 crevasses from ~95 km of 400 MHz frequency ground-penetrating radar data and compared these data with kinematic outputs derived from remotely-sensed ice surface velocities to develop a statistical method to estimate crevasse initiation threshold strain rate values. We found the MSZ to be dominated by simple shear and that surface shear strain rates proved best for predicting crevasse features, with regions of higher shear strain rate more likely to have a greater number of crevasses. In the surveyed portion of our study region, values of shear strain rate and vorticity rate derived from the MEaSUREs2 velocity dataset range between 0.005–0.020 and 0.006–0.022 a−1, respectively, with crevasses located at ≥0.011 and ≥0.013 a−1. While threshold values from this study cannot be directly applied to other glacial environments, the method described here should allow for the study of shear margin evolution and assessment of localized damage and weakening processes in other locations where in situ data are available.

scholarly journals Correction and accuracy improvement of non-parallel shear zone model

2018 ◽  
Vol 207 ◽  
pp. 02002
Author(s):  
Yaoke Wang ◽  
Meng Kou ◽  
Wei Ding ◽  
Huan Ma ◽  
Liangshan Xiong
Keyword(s):  
Experimental Data ◽  
Cutting Force ◽  
Shear Zone ◽  
Coordinate Transformation ◽  
Chip Thickness ◽  
Zone Model ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Experimental Values ◽  
1045 Steel

When applying the non-parallel shear zone model to predict the cutting process parameters of carbon steel workpiece, it is found that there is a big error between the prediction results and the experimental values. And also, the former approach to obtain the relevant cutting parameters of the non-parallel shear zone model by applying coordinate transformation to the parallel shear zone model has a theoretical error – it erroneously regards the determinant (|J|) of the Jacobian matrix (J) in the coordinate transformation as a constant. The shape of the shear zone obtained when |J| is not constant is drew and it is found that the two boundaries of the shear zone are two slightly curved surfaces rather than two inclined planes. Also, the error between predicted values and experimental values of cutting force and cutting thrust is slightly smaller than that of constant |J|. A corrected model where |J| is a variable is proposed. Since the specific values of inclination of the shear zone (α, β), the thickness coefficient of the shear zone (as) and the constants related to the material (f0, p) are not given in the former work, a method to obtain the above-mentioned five constants by solving multivariable constrained optimization problem based on experimental data was also proposed; based on the obtained experimental data of AISI 1045 steel workpiece cutting force, cutting thrust, chip thickness, the results of five above-mentioned model constants are obtained. It is found that, compared with prediction from uncorrected model, the cutting force and cutting thrust of AISI 1045 steel predicted by the corrected model with the obtained constants has a better agreement with the experimental values obtained by Ivester.

High shear strain rate rheometry of polymer melts

2009 ◽  
Vol 114 (2) ◽  
pp. 864-873 ◽  
Author(s):  
A. L. Kelly ◽  
T. Gough ◽  
B. R. Whiteside ◽  
P. D. Coates
Keyword(s):  
Strain Rate ◽  
Shear Strain ◽  
Polymer Melts ◽  
Shear Strain Rate ◽  
High Shear

Rheology of colloids

Surfactants ◽  
2019 ◽  
pp. 400-424
Author(s):  
Bob Aveyard
Keyword(s):  
Strain Rate ◽  
Shear Strain ◽  
Shear Thickening ◽  
Rheological Behaviour ◽  
Maxwell Model ◽  
Colloidal Dispersions ◽  
Shear Strain Rate ◽  
Plastic Behaviour ◽  
Shear Thickening Fluids ◽  
External Forces

Lyophobic colloidal dispersions, aggregated surfactant systems, and polymer solutions, as well as foams and emulsions, can all be deformed by weak external forces; rheology is the study of deformation and flow of materials. Various rheological quantities arising from the response of a material to shear are defined. For liquids the stress, τ‎, applied is related to the rate of deformation, that is, the shear strain rate, γ̇. For Newtonian fluids τ‎ and γ̇ are linearly related and τ‎ / γ̇ is the viscosity, η‎. Other nonlinear relationships correspond to shear thinning and shear thickening fluids and to plastic behaviour in which there is a yield stress. Viscoelastic systems exhibit both viscous and elastic properties; such behaviour is often treated using the simple Maxwell model. Some illustrative experimentally observed rheological behaviour is presented.

scholarly journals Erebus Glacier Tongue, Mcmurdo Sound, Antarctica

1974 ◽  
Vol 13 (67) ◽  
pp. 27-35 ◽  
Author(s):  
G. Holdsworth
Keyword(s):  
Shear Stress ◽  
Strain Rate ◽  
Shear Strain ◽  
Longitudinal Strain ◽  
Strain Rates ◽  
Shear Strain Rate ◽  
Mcmurdo Sound ◽  
Glacier Tongue ◽  
The Past ◽  
Image Position

Examination of the past and present behaviour of the Erebus Glacier tongue over the last 60 years indicates that a major calving from the tongue appears to be imminent. Calculations of the regime of the tongue indicate that bottom melt rates may exceed 1 m a−1. By successive mapping of the ice tongue between the years 1947 and 1970, longitudinal strain-rates were determined using the change in distance between a set of 15 teeth, which are a prominent marginal feature of the tongue. Assuming a flow law for ice of the form where τ is the effective shear stress and is the effective shear strain-rate, values of the exponent n = 3 and B = 1 × 108 N m−2 are determined. These are in fair agreement with published values.

scholarly journals Deformation in the Vicinity of Ice Divides

1983 ◽  
Vol 29 (103) ◽  
pp. 357-373 ◽  
Author(s):  
Charles F. Raymond
Keyword(s):  
Finite Elements ◽  
Laminar Flow ◽  
Velocity Profile ◽  
Strain Rate ◽  
Shear Strain ◽  
Vertical Velocity ◽  
Flow Theory ◽  
Numerical Calculations ◽  
Shear Strain Rate ◽  
Horizontal Shear

AbstractNumerical calculations by finite elements show that the variation of horizontal velocity with depth in the vicinity of a symmetric, isothermal, non-slipping ice ridge deforming on a flat bed is approximately consistent with prediction from laminar flow theory except in a zone within about four ice thicknesses of the divide. Within this near-divide zone horizontal shear strain-rate is less concentrated near the bottom and downward velocity is less rapid in comparison to the flanks. The profiles over depth of horizontal and vertical velocity approach being linear and parabolic respectively. Calculations for various surface elevation profiles show these velocity profile shapes are insensitive to the ice-sheet geometry.

Numerical Investigation of Heat Partition in the Primary Shear Zone in Metal Cutting

2005 ◽  
Author(s):  
Vasant Pednekar ◽  
Vis Madhavan ◽  
Amir H. Adibi-Sedeh
Keyword(s):  
Partition Coefficient ◽  
Strain Rate ◽  
Shear Zone ◽  
Metal Cutting ◽  
Plastic Material ◽  
Shear Plane ◽  
Analytical Models ◽  
Machined Surface ◽  
Element Analysis ◽  
Heat Partition

The fraction of heat generated in the primary shear zone that is conducted into the workpiece is a key factor in the calculation of the shear plane temperature and in calculating the cutting forces based on material flow stress. Accurate analytical, numerical, or experimental determination of this heat partition coefficient is not available to date. This study utilizes a new approach to obtain the heat partition coefficient for the primary shear zone using results for strain, strain rate, and temperature distribution obtained from a coupled thermo-mechanical finite element analysis of machining. Different approaches, using strain rate and equivalent strain, are used for calculating the total plastic power in the primary shear zone and the heat generated by plastic deformation below the plane of the machined surface. The heat carried away by the workpiece is obtained by calculating the heat flow by convection in regions where the conduction is expected to be small. We have used an elastic perfectly plastic material model and constant thermal properties to mimic the assumptions used in analytical models. The fraction of the total heat generated in the primary shear zone that is conducted into the machined workpiece is found and compared to the prediction of different analytical models. It is found that for most of the cutting conditions, the values of heat partition coefficient are closest to those provided by Weiner’s model.

scholarly journals The theory of plane plastic strain for anisotropic metals

1949 ◽  
Vol 198 (1054) ◽  
pp. 428-437 ◽  
Keyword(s):  
Plastic Strain ◽  
Strain Rate ◽  
Shear Strain ◽  
Plane Strain ◽  
Yield Criterion ◽  
Elliptic Functions ◽  
Shear Strain Rate ◽  
Maximum Shear Strain ◽  
Geometrical Properties ◽  
Plane Plastic

A yield criterion and plastic stress-strain relations are formulated for anisotropic metals deformed under conditions of plane strain. The equations are shown to be hyperbolic, the characteristics coinciding with the directions of maximum shear strain-rate. When the anisotropy is uniformly distributed, the variation of the stresses along the characteristics is expressed in terms of elliptic functions, and geometrical properties of the field of characteristics are established. The theory is applied to the problem of indentation by a flat die.

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