scholarly journals Sensitivity Analysis of Johnson-Cook Material Constants and Friction Coefficient Influence on Finite Element Simulation of Turning Inconel 718

Materials ◽  
2019 ◽  
Vol 12 (19) ◽  
pp. 3121 ◽  
Author(s):  
Xiaoli Qiu ◽  
Xianqiang Cheng ◽  
Penghao Dong ◽  
Huachen Peng ◽  
Yan Xing ◽  
...  
Keyword(s):  
Residual Stress ◽  
Sensitivity Analysis ◽  
Finite Element ◽  
Friction Coefficient ◽  
Constitutive Model ◽  
Cutting Force ◽  
Inconel 718 ◽  
Coulomb Friction ◽  
Cutting Conditions ◽  
Simulation Results

The Johnson-Cook (J-C) constitutive model, including five material constants (A, B, n, C, m), and the Coulomb friction coefficient (μ) are critical preprocessed data in machining simulations. Before they become reliable preprocessed data, investigating these parameters’ effect on simulation results benefits parameter-selecting. This paper aims to investigate the different influence of five settings of the J-C constitutive equation and Coulomb friction coefficient on the turning simulation results of Inconel 718 under low-high cutting conditions, including residual stress, chip morphology, cutting force and temperature. A three-dimensional (3-D) finite element model was built, meanwhile, the reliability of the model was verified by comparing the experiment with the simulation. Sensitivity analysis of J-C parameters and friction coefficient on simulation results at low-high cutting conditions was carried out by the hybrid orthogonal test. The results demonstrate that the simulation accuracy of Inconel 718 is more susceptible to strain hardening and thermal softening in the J-C constitutive model. The friction coefficient only has significant effects on axial and radial forces in the high cutting condition. The influences of the coefficient A, n, and m on the residual stress, chip thickness, cutting force and temperature are especially significant. As the cutting parameters increase, the effect of the three coefficients will change visibly. This paper provides direction for controlling simulation results through the adjustment of the J-C constitutive model of Inconel 718 and the friction coefficient.

Cutting performance investigation based on the variable friction model by considering sliding velocity and limiting stress

2020 ◽  
Vol 234 (8) ◽  
pp. 1113-1123
Author(s):  
Xin Li ◽  
Zhenyu Shi ◽  
Ningmin Duan ◽  
Peng Cui ◽  
Shuai Zhang ◽  
...  
Keyword(s):  
Finite Element ◽  
Friction Coefficient ◽  
Finite Element Model ◽  
Cutting Force ◽  
Element Model ◽  
Friction Model ◽  
Rake Face ◽  
Sliding Velocity ◽  
Variable Friction ◽  
Simulation Results

Fast and accurate cutting force prediction is still one of the most complex problems and challenges in the machining research community. In this study, a modified finite element model is presented to predict cutting force and cutting length in turning operations of AISI 1018. Unlike the existing research, in which the mean friction coefficient μ was taken, a variable friction coefficient μ involving the sliding velocity between chip and tool is presented in this article. The sticking–sliding friction model is adopted, and the maximum limiting stress in sticking region is calculated by considering the thermal softening and normal stress distribution. Experiments have been performed for machining AISI 1018 using tungsten carbide tool, and simulation results have been compared to experiments. The simulation results of the modified finite element model have shown better outputs in predicting cutting force, tangential force, and tool–chip contact length on the rake face. The results of this article not only are meaningful to optimize tool design and cutting parameters but also can provide a clear understanding of contact behavior between tool rake face and chip.

Influence of Laser Shock Processing on the Weld Line and Finite Element Simulation

2011 ◽  
Vol 464 ◽  
pp. 627-631
Author(s):  
Jie Zhang ◽  
Ai Hua Sun ◽  
Le Zhu ◽  
Xiang Gu
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Welding Residual Stress ◽  
Laser Shock ◽  
Analysis Software ◽  
Laser Shock Processing ◽  
Element Analysis ◽  
Welding Line ◽  
Simulation Results ◽  
Shock Processing

Welding residual stress is one of the main factors that affect the strength and life of components. In order to explore the effect on residual stress of welding line by laser shock processing, finite element analysis software ANSYS is used to simulate the welding process, to calculate the distribution of welding residual stress field. On this basis, then AYSYS/LS-DYNA is used to simulate the laser shock processing on welding line. Simulation results show that residual stress distributions of weld region, heat-affected region and matrix by laser shock processing are clearly improved, and the tensile stress of weld region effectively reduce or eliminate. The simulation results and experimental results are generally consistent, it offer reasons for parameter optimization of welding and laser shock processing by finite element analysis software.

Effect of the Friction Coefficient on Large Strain Extrusion Machining

2013 ◽  
Vol 273 ◽  
pp. 138-142 ◽  
Author(s):  
Ping Lin ◽  
Zi Chun Xie ◽  
Qing Li
Keyword(s):  
Finite Element ◽  
Friction Coefficient ◽  
Nanostructured Materials ◽  
Deformation Behavior ◽  
Large Strain ◽  
Effective Strain ◽  
Finite Element Simulations ◽  
Friction Coefficients ◽  
Simulation Results

The present study focused on the influence of the friction coefficient on the deformation behavior in large strain extrusion machining (LSEM). A series of simulation results of effective strain were obtained under different friction coefficients by conducting finite element simulations with a FEM code. The results show that LSEM can produce different effective strains by changing the friction coefficients, thus enabling the fabrication of bulk nanostructured materials. An analysis of the variation of effective strain through the chip demonstrated that the chip deformed much more inhomogeneously when the friction coefficient became larger. The obtained results can offer valuable guidelines for later LSEM studies.

Model-based sensitivity analysis of machining-induced residual stress under minimum quantity lubrication

2015 ◽  
Vol 231 (9) ◽  
pp. 1528-1541 ◽  
Author(s):  
Xia Ji ◽  
Steven Y Liang
Keyword(s):  
Residual Stress ◽  
Sensitivity Analysis ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Minimum Quantity Lubrication ◽  
Cutting Parameters ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Mixture Ratio ◽  
Minimum Quantity

This article presents a sensitivity analysis of residual stress based on the verified residual stress prediction model. The machining-induced residual stress is developed as a function of cutting parameters, tool geometry, material properties, and lubrication conditions. Based on the residual stress predictive model, the main effects of the cutting force, cutting temperature, and residual stress are quantitatively analyzed through the cosine amplitude method. The parametric study is carried out to investigate the effects of minimum quantity lubrication parameters, cutting parameters, and tool geometry on the cutting performances. Results manifest that the cutting force and residual stress are more sensitive to the heat transfer coefficient and the depth of cut, while the cutting temperature is more sensitive to the cutting speed. Large maximum compressive residual stress is obtained under a lower flow rate of minimum quantity lubrication, small depth of cut, and the proper air–oil mixture ratio. This research can support the controlling and optimization of residual stress in industrial engineering by strategically adjusting the application parameters of minimum quantity lubrication.

Investigating the Effects of the Friction Coefficient and Tool Geometry on the Cup Thickness in the Deep Drawing Process of SPXI250 Alloy

2013 ◽  
Author(s):  
Iman Rostamsowlat ◽  
Ahmad Afsari ◽  
Maziar Janghorban
Keyword(s):  
Finite Element ◽  
Friction Coefficient ◽  
Deep Drawing ◽  
The Other ◽  
Tool Geometry ◽  
Drawing Process ◽  
Nose Radius ◽  
Deep Drawing Process ◽  
Simulation Results ◽  
Thickness Variations

In this paper, effects of friction coefficient and tool geometry on the thickness variations of a cylindrical cup were studied. Blank is made of SPXI250 alloy sheet which was analyzed by Finite Element Method (FEM). This not been studied yet. Finite Element modeling of the deep drawing process was conducted using ABAQUS/EXPLICIT software. A set of appropriate die and punch were designed for experimental tests. The results of the simulation showed that a change in the friction coefficient of the die-blank interface leads to a significant changes in the cup thickness. Moreover, the results revealed that the influence of die nose radius on the final cup thickness variations is greater than that of the punch nose radius. The simulation results of this study were compared with the experimental results and those of the other investigators’. The comparisons of the experimental and simulation results with those of the other researchers were so satisfactory.

The Influence of Residual Stress on the Machining Deformation

2012 ◽  
Vol 426 ◽  
pp. 172-176
Author(s):  
Hun Guo
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Finite Element Model ◽  
Simulation Model ◽  
Elasticity Theory ◽  
Initial Stress ◽  
Fem Simulation ◽  
Element Model ◽  
Fem Model ◽  
Simulation Results

The key problems in 2D FEM simulation such as the establishment of finite element model, the initial stress loading, the distortion appraisal are solved and 2D FEM simulation model is built to analyze the milling distortion caused by the residual stress. The FEM model is verified by the elasticity theory. Some machining cases are simulated by using of the FEM model. The machining distortion caused by residual stress are analyzed and summarized using the simulation results.

Finite Element Analysis of Cutting Forces in High Speed Machining

2006 ◽  
Vol 532-533 ◽  
pp. 753-756 ◽  
Author(s):  
Jun Zhao ◽  
Xing Ai ◽  
Zuo Li Li
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Fem Simulation ◽  
Chip Thickness ◽  
Cutting Conditions ◽  
Cutting Process ◽  
Undeformed Chip Thickness ◽  
High Speed Cutting

The Finite Element Method (FEM) has proven to be an effective technique to investigate cutting process so as to improve cutting tool design and select optimum cutting conditions. The present work focuses on the FEM simulation of cutting forces in high speed cutting by using an orthogonal cutting model with variant undeformed chip thickness under plane-strain condition to mimic intermittent cutting process such as milling. High speed cutting of 45%C steel using uncoated carbide tools are simulated as the application of the proposed model. The updated Lagrangian formulation is adopted in the dynamic FEM simulation in which the normalized Cockroft and Latham damage criterion is used as the ductile fracture criterion. The simulation results of cutting force components under different cutting conditions show that both the thrust cutting force and the tangential cutting force increase with the increase in undeformed chip thickness or feed rate, whereas decrease with the increase in cutting speed. Some important aspects of modeling the high speed cutting are discussed as well to expect the future work in FEM simulation.

Finite Element Model of Schallamach Waves in Belt-Drives

2019 ◽  
Author(s):  
Mohammed Khattab ◽  
Tamer Wasfy
Keyword(s):  
Finite Element ◽  
Friction Coefficient ◽  
Finite Element Model ◽  
Wave Phenomenon ◽  
Coulomb Friction ◽  
Element Model ◽  
Belt Drive ◽  
High Fidelity ◽  
Stick Slip ◽  
Belt Drives

Abstract The objective of this study is to investigate if a high-fidelity finite element model can predict the Schallamach wave phenomenon in belt-drives. To this end a computational model which closely mimics a recently developed one-pulley experimental belt-drive apparatus, was created. The dynamic response predicted by the model is compared to the experiment results in order to demonstrate that the model can be used to predict the Schallamach wave phenomenon. Furthermore, the model is used to investigate the roles of Coulomb friction coefficient, adhesion, and torque direction on stick-slip instability effects.

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