Finite Element Analysis of the Influence of the Material Constitutive Law Formulation on the Chip Formation Process During a High Speed Metal Cutting

2012 ◽  
Author(s):  
Adinel Gavrus ◽  
Pascal Caestecker ◽  
Eric Ragneau
Keyword(s):  
Finite Element ◽  
Formation Process ◽  
Chip Formation ◽  
High Speed ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Constitutive Law ◽  
Cutting Process ◽  
Contact Friction ◽  
Numerical Predictions

During the last decades, the importance of machining in manufacturing industry has required rigorous scientific studies concerning the chip formation process in order to determine optimal speeds, feeds or other technological parameters. For all types of machining including turning, milling, grinding, honing or lapping, the phenomenon of chip formation is similar in terms of the local interaction between the tool and the work piece. Because of the intensive use of CNC machine tools producing parts at ever-faster rates, it has become important to provide analysis of high speed cutting where complex loading conditions occur during the fabrication process: high gradients of the thermo-mechanical variables, strong nonlinearities of the thermo-mechanical coupling, large plastic strains, extremely high strain rates compared to that of other forming processes, important influence of the contact friction and of the microstructure evolution. Today many scientific researches are focalized on finite element analyses of the chip formation and of its morphology evolution during a high speed metals cutting process. To improve the quality of the numerical predictions, a better description of the local shear band formation is needed, using adequate rheological models. On this point of view this paper deals with the influence of the rheological behavior formulation on the morphology and geometry of the chip formation during a finite element simulation of a high speed metal cutting process. Numerical simulations of a high speed orthogonal cutting of special steels are employed to analysis the sensitivity of the numerical results describing the local cutting area with respect to different rheological laws: Norton-Hoff or Cowper-Symonds model, Johnson-Cook one or Zerilli-Armstrong formulation. To obtain a better description of the local material loadings and to take into account the important gradient of the strain rate, plastic strain and temperature values, a more adequate constitutive model is proposed by the author.

FEM Simulation of the Residual Stress in the Machined Surface Layer for High-Speed Machining

2006 ◽  
Vol 315-316 ◽  
pp. 140-144 ◽  
Author(s):  
Su Yu Wang ◽  
Xing Ai ◽  
Jun Zhao ◽  
Z.J. Lv
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Surface Layer ◽  
Residual Stresses ◽  
High Speed ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
High Speed Machining ◽  
Machined Surface ◽  
Cutting Model

An orthogonal cutting model was presented to simulate high-speed machining (HSM) process based on metal cutting theory and finite element method (FEM). The residual stresses in the machined surface layer were obtained with various cutting speeds using finite element simulation. The variations of residual stresses in the cutting direction and beneath the workpiece surface were studied. It is shown that the thermal load produced at higher cutting speed is the primary factor affecting the residual stress in the machined surface layer.

3D Finite Element Modeling of the Machining of Ti6Al4V Alloys

2011 ◽  
Vol 189-193 ◽  
pp. 1926-1929 ◽  
Author(s):  
Ji Hong Yang ◽  
Shou Jin Sun ◽  
Milan Brandt ◽  
Wen Yi Yan
Keyword(s):  
Finite Element ◽  
Chip Formation ◽  
Element Model ◽  
Cutting Process ◽  
Temperature Fields ◽  
Contact Friction ◽  
Dynamic Effects ◽  
3D Finite Element ◽  
Mechanical Coupling ◽  
Damage Law

A 3D finite element model of the machining of Ti6Al4V alloy has been developed. This model is able to simulate the formation of continuous or discontinuous chips during the cutting process that depends on the cutting conditions. In this model, the yield stress is considered as a function of the strain, the strain rate and the temperature. The dynamic effects, thermo-mechanical coupling, constitutive damage law and contact friction are taken into account. The stresses and temperature fields, chip formation and tool forces are obtained at different stages of the cutting process.

Basic Mechanics of the Metal-Cutting Process

1944 ◽  
Vol 11 (3) ◽  
pp. A168-A175 ◽  
Author(s):  
M. Eugene Merchant
Keyword(s):  
High Speed ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Cutting Edge ◽  
Cutting Process ◽  
Work Piece ◽  
Machining Operations ◽  
Work Done ◽  
Metal Work

Abstract The author presents a mathematical analysis of the geometry and mechanics of the metal-cutting process, covering two common types of geometry which occur in cutting. This analysis offers a key for the study of engineering problems in the field of metal cutting in terms of such fundamental quantities as strain, rate of shear, friction between chip and tool, shear strength of the metal, work done in shearing the metal and in overcoming friction, etc. The two cases covered are, in essence, that of a straight-edged cutting tool moving relative to the work-piece in a direction perpendicular to its cutting edge, termed “orthogonal cutting,” and that of a similar cutting tool so set that the cutting edge is oblique to the direction of relative motion of tool and work, termed “oblique cutting.” Equations are developed which permit the calculation of such quantities as those just enumerated from readily observable values. The theoretical findings are particularly applicable and significant in the case of present-day high-speed machining operations with sintered-carbide tools.

Computer Simulation of AISI D2 Orthogonal Cutting Using Finite Element Method

2012 ◽  
Vol 499 ◽  
pp. 39-44
Author(s):  
L. Yan ◽  
Feng Jiang ◽  
Y.M. Rong
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Cutting Tool ◽  
Orthogonal Cutting ◽  
Damage Model ◽  
Chip Morphology ◽  
Simulation Method ◽  
Cutting Process ◽  
Aisi D2 ◽  
Cutting Processes

This paper presented a finite element simulation model for the analysis of AISI D2 orthogonal cutting process using TiAlN coated inserts. Firstly, AISI D2 material constitutive model was built based on power law model, which was used in the FEM codes to describe the effect of strain, strain rate and temperature on the material flow stress. In modeling the chip formation, a damage model was employed to predict the chip separation. Then cutting edge radius and thickness of TiAlN coating of cutting tool were measured by SEM. Friction coefficients of cutting tool against AISI D2 steel were obtained by ball-on-plate friction tests on UMT-2 high speed tribometer. Finally, finite element simulations of AISI D2 orthogonal cutting processes were performed using AdvantedgeTM software. The simulated results of cutting forces and chip morphology showed good agreement with the experimental results, which validated the reliability of the cutting process simulation method.

scholarly journals Dynamic Recrystallization Observed at the Tool/Chip Interface in Machining

2015 ◽  
Vol 651-653 ◽  
pp. 1223-1228
Author(s):  
Yannick Senecaut ◽  
Michel Watremez ◽  
Julien Brocail ◽  
Laurence Fouilland-Paillé ◽  
Laurent Dubar
Keyword(s):  
Finite Element ◽  
Dynamic Recrystallization ◽  
Finite Element Model ◽  
Rheological Behavior ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Numerical Results ◽  
Constitutive Law ◽  
Rheological Models

In numerical approaches for high speed machining, the rheological behavior of machined materials is usually described by a Johnson Cook law. However, studies have shown that dynamic recrystallization phenomena appear during machining in the tool/chip interface. The Johnson Cook constitutive law does not include such phenomena. Thus, specific rheological models based on metallurgy are introduced to consider these dynamic recrystallization phenomena. Two empirical models proposed by Kim et al. (2003) and Lurdos (2008) are investigated in machining modeling. A two-dimensional finite element model of orthogonal cutting, using an Arbitrary Lagrangian-Eulerian (ALE) formulation, is developed with the Abaqus/explicit software. Specific rheological models are implemented in the calculation code thanks to a subroutine. This finite element model can then predict chip formation, interfacial temperatures, chip-tool contact length, cutting forces and chip thickness with also and especially the recrystallized area. New specific experiments on an orthogonal cutting test bench are conducted on AISI 1045 steel specimens with an uncoated carbide tool. Many tests are performed and results are focused on total chip thicknesses and recrystallized chip thicknesses. Finally, compared to numerical results got with a Johnson Cook law, numerical results obtained using specific rheological models to take into account dynamic recrystallization phenomena are very close to experimental results. This work shows also the influence of rheological behavior laws on predicted results in the modeling of high speed modeling.

scholarly journals Finite Element Modeling of the Effect of Tool Rake Angle on Cutting Force and Tool Temperature during High Speed Machining of AISI 1045 Steel

2014 ◽  
Vol 939 ◽  
pp. 194-200
Author(s):  
Shamsuddin Sulaiman ◽  
Mohd K.A. Ariffin ◽  
A. Roshan
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
High Speed ◽  
Metal Cutting ◽  
Rake Angle ◽  
Cutting Process ◽  
High Speed Machining ◽  
Tool Temperature ◽  
Aisi 1045 ◽  
Cutting Speeds

A finite element model (FEM) of an orthogonal metal-cutting process is used to study the influence of tool rake angle on the cutting force and tool temperature. The model involves Johnson-Cook material model and Coulomb’s friction law. A tool rake angle ranging from 0° to 20° and a cutting speed ranging from 300 to 600 m/min were considered in this simulation. The results of this simulation work are consistent optimum tool rake angle for high speed machining (HSM) of AISI 1045 medium carbon steel. It was observed that there was a suitable rake angle between 10° and 18° for cutting speeds of 300 and 433 m/min where cutting force and temperature were lowest. However, there was not optimum rake angle for cutting speeds of 550 and 600 m/min. This paper can contribute in optimization of cutting tool for metal cutting process.

Numerical Analysis of Metal Cutting With Chamfered and Blunt Tools

2002 ◽  
Vol 124 (2) ◽  
pp. 178-188 ◽  
Author(s):  
M. R. Movahhedy, ◽  
Y. Altintas, ◽  
M. S. Gadala,
Keyword(s):  
Formation Process ◽  
Chip Formation ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Edge ◽  
Hard Materials ◽  
Ale Finite Element Method ◽  
Diffusion Wear ◽  
Process Simulations

In high speed machining of hard materials, tools with chamfered edge and materials resistant to diffusion wear are commonly used. In this paper, the influence of cutting edge geometry on the chip removal process is studied through numerical simulation of cutting with sharp, chamfered or blunt edges and with carbide and CBN tools. The analysis is based on the use of ALE finite element method for continuous chip formation process. Simulations include cutting with tools of different chamfer angles and cutting speeds. The study shows that a region of trapped material zone is formed under the chamfer and acts as the effective cutting edge of the tool, in accordance with experimental observations. While the chip formation process is not significantly affected by the presence of the chamfer, the cutting forces are increased. The effect of cutting speed on the process is also studied.

A Coupled Finite Element Model of Thermo-Elastic-Plastic Large Deformation for Orthogonal Cutting

1992 ◽  
Vol 114 (2) ◽  
pp. 218-226 ◽  
Author(s):  
Z. C. Lin ◽  
S. Y. Lin
Keyword(s):  
Finite Element ◽  
Energy Density ◽  
Large Deformation ◽  
Chip Formation ◽  
Strain Energy Density ◽  
Strain Energy ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Elastic Plastic ◽  
Chip Separation

In this paper, a coupled model of the thermo-elastic-plastic material under large deformation for orthogonal cutting is constructed. A chip separation criterion based on the critical value of the strain energy density is introduced into the analytical model. A scheme of twin node processing and a concept of loading/unloading are also presented for chip formation. The flow stress is taken as a function of strain, strain rate and temperature in order to reflect realistic behavior in metal cutting. The cutting tool is incrementally advanced forward from an incipient stage of tool-workpiece engagement to a steady state of chip formation. The finite difference method is adopted to determine the temperature distribution within the chip and tool, and a finite element method, which is based on the thermo-elastic-plastic large deformation model, is used to simulate the entire metal cutting process. Finally, the chip geometry, residual stresses in the machined surface, temperature distributions within the chip and tool, and tool forces are obtained by simulation. The calculated cutting forces agree quite well with the experimental results. It has also been verified that the chip separation criterion value based on the strain energy density is a material constant and is independent of uncut chip thickness.

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