A Metallo-Thermomechanically Coupled Analysis of Orthogonal Cutting of AISI 1045 Steel

2012 ◽  
Vol 134 (5) ◽  
Author(s):  
Hongtao Ding ◽  
Yung C. Shin
Keyword(s):  
Experimental Data ◽  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Machining Process ◽  
Coupled Analysis ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Materials often behave in a complicated manner involving deeply coupled effects among stress/stain, temperature, and microstructure during a machining process. This paper is concerned with prediction of the phase change effect on orthogonal cutting of American Iron and Steel Institute (AISI) 1045 steel based on a true metallo-thermomechanical coupled analysis. A metallo-thermomechanical coupled material model is developed and a finite element model (FEM) is used to solve the evolution of phase constituents, cutting temperature, chip morphology, and cutting force simultaneously using abaqus. The model validity is assessed using the experimental data for orthogonal cutting of AISI 1045 steel under various conditions, with cutting speeds ranging from 198 to 879 m/min, feeds from 0.1 to 0.3 mm, and tool rake angles from −7 deg to 5 deg. A good agreement is achieved in chip formation, cutting force, and cutting temperature between the model predictions and the experimental data.

A Metallo-Thermo-Mechanically Coupled Analysis of Orthogonal Cutting of AISI 1045 Steel

2012 ◽  
Author(s):  
Hongtao Ding ◽  
Yung C. Shin
Keyword(s):  
Experimental Data ◽  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Machining Process ◽  
Coupled Analysis ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Materials often behave in a complicated manner involving deeply coupled effects among stress/stain, temperature and microstructure during a machining process. This paper is concerned with prediction of the phase change effect on orthogonal cutting of AISI 1045 steel based on a true metallo-thermo-mechanical coupled analysis. A metallo-thermo-mechanical coupled material model is developed, and a finite element model is used to solve the evolution of phase constituents, cutting temperature, chip morphology, and cutting force simultaneously using ABAQUS. The model validity is assessed using the experimental data for orthogonal cutting of AISI 1045 steel under various conditions, with cutting speeds ranging from 198 to 879 m/min, feeds from 0.1 to 0.3 mm, and tool rake angles from −7° to 5°. A good agreement is achieved in chip formation, cutting force and cutting temperature between the model predictions and the experimental data.

CEL FEM Investigation of Effects of Microgrooved Cutting Tools in High Speed Machining of AISI 1045 Steel

2017 ◽  
Author(s):  
Han Wu ◽  
Nick H. Duong ◽  
J. Ma ◽  
Shuting Lei
Keyword(s):  
Cutting Force ◽  
High Speed ◽  
Cutting Tools ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
High Speed Machining ◽  
Rake Face ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

In this paper, the commercial FEM software package Abaqus is used to investigate the effects of microgrooved cutting tools in high speed orthogonal cutting of AISI 1045 steel. Microgrooves are designed and fabricated on the rake face of cemented carbide (WC/Co) cutting inserts. A coupled Eulerian-Lagrangian (CEL) finite element model is developed based on Abaqus to solve the evolution of the cutting temperature, chip morphology, cutting force, and phase constitutes simultaneously. This model is validated by comparing the numerical results with the experimental data for orthogonal high speed cutting of AISI 1045 steel with various cutting conditions. In addition, this model is also validated by comparing with the experimental data of regular tool and microgrooved cutting tool under the cutting speed of 120m/min. This validated CEL FEM model is then utilized to investigate the effects of microgrooved cutting tools on the phase transformation, cutting force, cutting temperature, and chip morphology in high speed orthogonal cutting of AISI 1045. The effects of microgroove width, edge distance (the distance from cutting edge to the first microgroove), and microgroove depth are examined and assessed in terms of cutting force, cutting temperature, chip morphology, and phase transformation. It is found that this CEL FEM model can capture the essential features of orthogonal high speed cutting of AISI 1045 using microgrooved cutting tools. It is also concluded that microgrooved cutting tools can not effectively reduce the cutting force in high speed machining, which is contrary to the conclusion obtained for low speed machining in previous research. However, microgrooves on the rake face have influence on the austenite percentage in the chip near the rake face. This research provides insightful guidance for optimizing the cutting performance in terms of cutting temperature, cutting force, chip morphology, and phase transformation in high speed machining of AISI 1045 steel.

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.

Fuzzy Modeling to Simulate Surface Roughness in CNC Turning of AISI 1045 Steel

2011 ◽  
Vol 486 ◽  
pp. 262-265
Author(s):  
Amit Kohli ◽  
Mudit Sood ◽  
Anhad Singh Chawla
Keyword(s):  
Experimental Data ◽  
Surface Roughness ◽  
Process Parameters ◽  
Fuzzy Model ◽  
Fuzzy Modeling ◽  
Cnc Machine ◽  
Model Based ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

The objective of the present work is to simulate surface roughness in Computer Numerical Controlled (CNC) machine by Fuzzy Modeling of AISI 1045 Steel. To develop the fuzzy model; cutting depth, feed rate and speed are taken as input process parameters. The predicted results are compared with reliable set of experimental data for the validation of fuzzy model. Based upon reliable set of experimental data by Response Surface Methodology twenty fuzzy controlled rules using triangular membership function are constructed. By intelligent model based design and control of CNC process parameters, we can enhance the product quality, decrease the product cost and maintain the competitive position of steel.

New Thermal Issues on the Modelling of Tool-Workpiece Interaction: Application to Dry Cutting of AISI 1045 Steel

2011 ◽  
Vol 223 ◽  
pp. 286-295 ◽  
Author(s):  
Cédric Courbon ◽  
Tarek Mabrouki ◽  
Joël Rech ◽  
Denis Mazuyer ◽  
Enrico D'Eramo
Keyword(s):  
Heat Flux ◽  
Hot Spot ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Contact Length ◽  
Dry Cutting ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Carbide

The present work proposes to enhance the thermal interface denition in Finite Element (FE) simulations of machining. A user subroutine has been developed in Abaqus/Explicit © to implement a new experimentally-based heat partition model extracted from tribological tests. A 2D Arbitrary-Lagragian-Eulerian (ALE) approach is employed to simulate dry orthogonal cutting of AISI 1045 steel with coated carbide inserts. Simulation results are compared to experimental ones over a whole range of cutting speeds and feed rates in terms of average cutting forces, chip thickness, tool chip contact length and heat flux. This study emphasizes that heat transfer and temperature distribution in the cutting tool are drastically in uenced by the thermal formulation used at the interface. Consistency of the numerical results such as heat flux transmitted to the tool, peak temperature as well as hot spot location can be denitively improved.

A modified Zerilli–Armstrong constitutive model for simulating severe plastic deformation of a steel alloy

2021 ◽  
pp. 095440542110609
Author(s):  
Muralimohan Gurusamy ◽  
Balkrishna C Rao
Keyword(s):  
Plastic Deformation ◽  
Severe Plastic Deformation ◽  
Constitutive Relation ◽  
Orthogonal Cutting ◽  
Chip Morphology ◽  
Steel Alloy ◽  
Face Centered Cubic ◽  
Aisi 1045 Steel ◽  
Face Centered ◽  
1045 Steel

A modified Zerilli–Armstrong model has been proposed and validated in previous works for simulating distinct deformation mechanisms of continuous-shear and shear-localization during severe plastic deformation of a face centered cubic alloy. In this paper, the validity of the modified Zerilli–Armstrong model has been further tested by using it for modeling the severe plastic deformation of another face centered cubic material, a steel alloy. In particular, the modified Zerilli–Armstrong model is used as a constitutive relation for simulating behavior of AISI 1045 steel alloy while undergoing severe plastic deformation through orthogonal and plane-strain machining. Accordingly, the performance of the constitutive relation in predicting flow stress distribution along the primary shear zone is validated by comparing with forecasts made using the distributed primary zone deformation, the original Zerilli-Armstrong and Johnson-Cook models. Furthermore, finite element simulations of orthogonal cutting of this steel alloy were carried out, and good agreement was observed between the predicted chip morphology and attendant cutting forces with experimental values reported in literature for a range of cutting conditions. The force predictions also fared better compared to those predicted by using the Zerilli-Armstrong and Johnson-Cook models. These validations provide further corroboration of using the modified Zerilli–Armstrong model as a constitutive relation for simulating the behavior of face-centered cubic materials under conditions of high plastic strains and also high strain-rates.

Prediction of Adiabatic Shear Critical Cutting Conditions of hardened AISI 1045 Steel with Different Hardness

2013 ◽  
Vol 589-590 ◽  
pp. 134-139
Author(s):  
Guo He Li ◽  
Yu Jun Cai ◽  
Hou Jun Qi
Keyword(s):  
Model Building ◽  
Orthogonal Cutting ◽  
Adiabatic Shear ◽  
Cutting Conditions ◽  
Constitutive Relationship ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Relationship Of ◽  
1045 Steel ◽  
Cutting Experiments

A method for building the constitutive relationship based on the J-C model and hardness is presented through considering the influence of hardness on the yield strength and the tensile strength. A constitutive relationship of hardened AISI 1045 is built by this method and the adiabatic shear critical cutting conditions of three kinds of hardness AISI 1045 steel are prediction through a model building by the linear pertubation analysis which considering the influence of compression stress of the primary shear zone, the cutting conditions and the constitutive relationship. For proving the prediction results, some orthogonal cutting experiments are performed to get the critical cutting conditions of adiabatic shear. The comparison shows that the prediction results are consistent with that of experiments.

High Speed Machining of Hardened AISI 1045 Steel

2016 ◽  
Vol 861 ◽  
pp. 63-68 ◽  
Author(s):  
Xue Ping Zhang ◽  
Shu Biao Wu ◽  
Zhen Qiang Yao ◽  
Li Feng Xi
Keyword(s):  
High Speed ◽  
Shear Bands ◽  
Chip Morphology ◽  
Machining Parameters ◽  
Chip Breaker ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
High Feed ◽  
Serrated Chips ◽  
1045 Steel

Hardened AISI 1045 steel implemented in machine tool spindle was previously ground using grinding operation. This research aims to address the feasibility of hard turning AISI 1045 using PCBN tool with chip breaker under dry condition. Chip morphology, cutting force and temperature were measured, analyzed and correlated with machining parameters. Experimental results demonstrate that serrated chips are generated at high speeds, high feed rate is an assistant to promote serrated chips, and chip breaker can help break chip into acceptable lengths. Cutting forces were characterized with periodic fluctuation along three directions as chips are serrated. Temperature at machined zone can reach as high as 1200°C, which indicates that adiabatic shear bands can be successfully achieved during the machining of hardened AISI 1045 steel without applying lubricants.

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