Chip Morphology Studies Using Separate Fracture Toughness Values for Chip Separation and Serration in Orthogonal Machining Simulations

2018 ◽  
Author(s):  
Jaimeen Patel ◽  
Harish P. Cherukuri
Keyword(s):  
Damage Evolution ◽  
Damage Model ◽  
Equivalent Plastic Strain ◽  
Chip Morphology ◽  
Threshold Value ◽  
Threshold Values ◽  
Orthogonal Machining ◽  
Evolution Laws ◽  
On Chip ◽  
Chip Separation

It is well known that the chip morphology predictions in machining simulations depend on the separation criteria used for modeling chip formation. In this paper, we propose to use two different criteria for chip separation and serration along with the Johnson-Cook damage model. The threshold value for chip separation is determined from machining experiments using the methodologies discussed in Patel et al. [1]. In addition, two separate damage evolution laws for chip separation and serration are used. Our results indicate that the choice of the evolution law and the threshold values of Gc used for chip separation and serration have a significant effect on chip shape and other field variables such as the equivalent plastic strain, cutting force, temperature, etc.

scholarly journals Numerical Modeling and Analysis of Ti6Al4V Alloy Chip for Biomedical Applications

Materials ◽  
2020 ◽  
Vol 13 (22) ◽  
pp. 5236
Author(s):  
Waqas Saleem ◽  
Bashir Salah ◽  
Xavier Velay ◽  
Rafiq Ahmad ◽  
Razaullah Khan ◽  
...  
Keyword(s):  
Damage Model ◽  
Equivalent Plastic Strain ◽  
Chip Morphology ◽  
Cutting Parameters ◽  
Ti6al4v Alloy ◽  
Contact Friction ◽  
Fracture Mechanisms ◽  
Modeling And Analysis ◽  
Micro Scale ◽  
Chip Flow

The influence of cutting forces during the machining of titanium alloys has attained prime attention in selecting the optimal cutting conditions to improve the surface integrity of medical implants and biomedical devices. So far, it has not been easy to explain the chip morphology of Ti6Al4V and the thermo-mechanical interactions involved during the cutting process. This paper investigates the chip configuration of the Ti6Al4V alloy under dry milling conditions at a macro and micro scale by employing the Johnson-Cook material damage model. 2D modeling, numerical milling simulations, and post-processing were conducted using the Abaqus/Explicit commercial software. The uncut chip geometry was modeled with variable thicknesses to accomplish the macro to micro-scale cutting by adapting a trochoidal path. Numerical results, predicted for the cutting reaction forces and shearing zone temperatures, were found in close approximation to experimental ones with minor deviations. Further analyses evaluated the influence of cutting speeds and contact friction coefficients over the chip flow stress, equivalent plastic strain, and chip morphology. The methodology developed can be implemented in resolving the industrial problems in the biomedical sector for predicting the chip morphology of the Ti6Al4V alloy, fracture mechanisms of hard-to-cut materials, and the effects of different cutting parameters on workpiece integrity.

The Effect of Cutting Speed on Chip Formation Under Orthogonal Machining

1985 ◽  
Vol 107 (1) ◽  
pp. 55-63 ◽  
Author(s):  
D. Lee
Keyword(s):  
Chip Formation ◽  
Cutting Speed ◽  
Chip Morphology ◽  
High Cutting Speed ◽  
Orthogonal Machining ◽  
Localized Heating ◽  
On Chip ◽  
All Speeds ◽  
Cutting Speeds ◽  
Steel Chip

Orthogonal machining experiments were conducted at different cutting speeds ranging from 8.5 × 10−2 cm/s (0.17 ft/min) to about 2.5 × 102 cm/s (492.1 ft/min) with 6061-T6 aluminum, 4340 steel, and Ti-6A1-4V titanium to examine the chip formation process. The most pronounced effect of the cutting speed on chip morphology was observed with the titanium alloy; the chips remained segmented at all speeds, but became continuous macroscopically at high cutting speeds. The steel chip also became continuous and oxidized, showing the effect of localized heating. The changing chip morphology that is accompanied with decreasing normal force at the high cutting speed is rationalized on the basis of localized adiabatic heating, which is dependent on the thermal-mechanical properties of each material.

Modeling the hysteretic responses of RC shear walls under cyclic loading by an energy-based plastic-damage model for concrete

2019 ◽  
Vol 29 (1) ◽  
pp. 184-200
Author(s):  
Shen Zhang ◽  
Ming Cheng ◽  
Jie Wang ◽  
Jian-Ying Wu
Keyword(s):  
Cyclic Loading ◽  
Software Package ◽  
Damage Evolution ◽  
Failure Modes ◽  
Damage Model ◽  
Shear Walls ◽  
Benchmark Tests ◽  
Plastic Damage ◽  
Commercial Software Package ◽  
Evolution Laws

This paper addresses application of an energy-based plastic-damage model for concrete to the modeling of hysteretic responses of reinforced concrete (RC) shear walls. Both damage evolution and plastic flows are accounted for within the framework of thermodynamics, resulting in consistent energy-based damage evolution laws. The model is implemented in the commercial software package ABAQUS via the user-defined material subroutine and applied to two representative benchmark tests of RC shear walls under cyclic loading. It is shown that with the steel reinforcement properly accounted for, the energy-based plastic-damage model can capture realistically the failure modes, load capacities, and overall load–deformation responses of RC shear walls.

scholarly journals Investigation of Burn Cut Parameters and Model for One-Step Raise Excavation Based on Damage Evolution Mechanisms

Geofluids ◽  
2020 ◽  
Vol 2020 ◽  
pp. 1-16 ◽  
Author(s):  
Kai Liu ◽  
Jiadong Qiu
Keyword(s):  
Damage Evolution ◽  
Damage Zone ◽  
Damage Model ◽  
Threshold Value ◽  
Numerical Results ◽  
Good Effect ◽  
Charge Hole ◽  
Triangular Prism ◽  
Linear Charge Density ◽  
One Step

One-step raise excavation with burn cut is a kind of technology which use the drilling and blasting method to excavate the raise quickly. Due to the limitation of the free surface in burn cut, determination of cut parameters such as the length of burden and diameters of empty hole and charge hole is important to achieve a good effect of cut blasting. Meanwhile, the choice of the cut model is also crucial to form a proper opening. In this study, a modified Holmquist-Johnson-Cook (HJC) model, in which the tension-compression damage model and tension-compression strain rate effect model are considered, is embedded in the LS-DYNA software to investigate the damage evolution of rock in cut blasting. A simplified numerical model of burn cut is built in the LS-DYNA. The numerical results indicate that there is a threshold value of the burden length to maximize the opening. The empty hole has the effect of transferring blasting energy, and the effect becomes more obvious with the increase of the hole size. Moreover, the linear charge density of the prime cut hole can affect the compression and tension damage. Further, the comparison among four typical burn cut models are conducted based on numerical results. It demonstrates that triangular prism cut and doliform cut, which have more empty holes arrangement surrounding the prime cut hole, are better than spiral cut and diamond cut that with less empty holes locating one side of the prime cut hole in terms of energy efficiency and damage zone control.

scholarly journals A Modified Phase-Field Damage Model for Metal Plasticity at Finite Strains: Numerical Development and Experimental Validation

Metals ◽  
2020 ◽  
Vol 11 (1) ◽  
pp. 47
Author(s):  
Jelena Živković ◽  
Vladimir Dunić ◽  
Vladimir Milovanović ◽  
Ana Pavlović ◽  
Miroslav Živković
Keyword(s):  
Phase Field ◽  
Damage Evolution ◽  
Deformation Gradient ◽  
Damage Model ◽  
Steel Structures ◽  
Plasticity Model ◽  
Metal Plasticity ◽  
Damage And Fracture ◽  
Von Mises ◽  
Von Mises Plasticity

Steel structures are designed to operate in an elastic domain, but sometimes plastic strains induce damage and fracture. Besides experimental investigation, a phase-field damage model (PFDM) emerged as a cutting-edge simulation technique for predicting damage evolution. In this paper, a von Mises metal plasticity model is modified and a coupling with PFDM is improved to simulate ductile behavior of metallic materials with or without constant stress plateau after yielding occurs. The proposed improvements are: (1) new coupling variable activated after the critical equivalent plastic strain is reached; (2) two-stage yield function consisting of perfect plasticity and extended Simo-type hardening functions. The uniaxial tension tests are conducted for verification purposes and identifying the material parameters. The staggered iterative scheme, multiplicative decomposition of the deformation gradient, and logarithmic natural strain measure are employed for the implementation into finite element method (FEM) software. The coupling is verified by the ‘one element’ example. The excellent qualitative and quantitative overlapping of the force-displacement response of experimental and simulation results is recorded. The practical significances of the proposed PFDM are a better insight into the simulation of damage evolution in steel structures, and an easy extension of existing the von Mises plasticity model coupled to damage phase-field.

An improved nonlinear damage model of rocks considering initial damage and damage evolution

2020 ◽  
Vol 29 (7) ◽  
pp. 1117-1137 ◽  
Author(s):  
Wenlin Feng ◽  
Chunsheng Qiao ◽  
Shuangjian Niu ◽  
Zhao Yang ◽  
Tan Wang
Keyword(s):  
Damage Evolution ◽  
Least Squares Method ◽  
Damage Model ◽  
Creep Damage ◽  
Secondary Creep ◽  
Nonlinear Creep ◽  
Creep Failure ◽  
Initial Damage ◽  
Nonlinear Damage Model ◽  
Creep Damage Model

The experimental results show that the creep properties of the rocks are affected by the initial damage, and the damage evolution also has a significant impact on the time-dependent properties of the rocks during the creep. However, the effects of the initial damage and the damage evolution are seldom considered in the current study of the rocks' creep models. In this paper, a new nonlinear creep damage model is proposed based on the multistage creep test results of the sandstones with different damage degrees. The new nonlinear creep damage model is improved based on the Nishihara model. The influences of the initial damage and the damage evolution on the components in the Nishihara model are considered. The creep damage model can not only describe the changes in three creep stages, namely, the primary creep, the secondary creep, and the tertiary creep, but also reflect the influence of the initial damage and the damage evolution on creep failure. The nonlinear least squares method is used to determine the parameters in the nonlinear creep damage model. The consistency between the experimental data and the predicted results indicates the applicability of the nonlinear damage model to accurately predict the creep deformation of the rocks with initial damage.

Damage Evolution and Failure Modeling in Unidirectional Graphite/Epoxy Composite

2001 ◽  
Author(s):  
G. P. Tandon ◽  
R. Y. Kim
Keyword(s):  
Damage Evolution ◽  
Failure Modes ◽  
Epoxy Composite ◽  
Damage Model ◽  
Tensile Loading ◽  
Unidirectional Composite ◽  
Concentric Cylinder ◽  
Failure Modeling ◽  
Stress Levels

Abstract A study is conducted to examine and predict the micromechanical failure modes in a unidirectional composite when subjected to tensile loading parallel to the fibers. Experimental observations are made at some selected stress levels to identify the initiation and growth of micro damage during loading. The axisymmetric damage model of a concentric cylinder is then utilized to postulate and analyze some failure scenarios.

FE analysis of the effects of process representations on the prediction of residual stresses and chip morphology in the down-milling of Ti6Al4V

2021 ◽  
pp. 1-50
Author(s):  
Nejah Tounsi ◽  
Tahany El-Wardany
Keyword(s):  
Experimental Data ◽  
Residual Stresses ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Chip Morphology ◽  
Milling Process ◽  
Uncut Chip Thickness ◽  
Orthogonal Machining ◽  
Cutting Length ◽  
Sequential Cuts

Abstract Part I of these two-part papers will investigate the effect of three FEM representations of the milling process on the prediction of chip morphology and residual stresses (RS), when down-milling small uncut chips with thickness in the micrometer range and finite cutting edge radius. They are: i) orthogonal cutting with the mean uncut chip thickness t, obtained by averaging the uncut chip thickness over the cutting length, ii) orthogonal cutting with variable t, which characterizes the down-milling process and which is imposed on a flat surface of the final workpiece, and iii) modelling the true kinematics of the down milling process. The appropriate constitutive model is identified through 2D FEM investigation of the effects of selected constitutive equations and failure models on the prediction of RS and chip morphology in the dry orthogonal machining of Ti6Al4V and comparison to experimental measurements. The chip morphology and RS prediction capability of these representations is assessed using the available set of experimental data. Models featuring variable chip thickness have revealed the transition from continuous chip formation to the rubbing mode and have improved the predictions of residual stresses. The use of sequential cuts is necessary to converge toward experimental data.

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