An experimental and finite element investigation of chip separation criteria in metal cutting process

2021 ◽  
Author(s):  
Junli Li ◽  
Ziru Huang ◽  
Gang Liu ◽  
Qinglong An ◽  
Ming Chen
Keyword(s):  
Finite Element ◽  
Metal Cutting ◽  
Cutting Process ◽  
Chip Separation

A Finite Element Model of Orthogonal Metal Cutting

1985 ◽  
Vol 107 (4) ◽  
pp. 349-354 ◽  
Author(s):  
J. S. Strenkowski ◽  
J. T. Carroll
Keyword(s):  
Finite Element ◽  
Plastic Strain ◽  
Residual Stresses ◽  
Finite Element Model ◽  
Metal Cutting ◽  
Element Model ◽  
Effective Plastic Strain ◽  
Orthogonal Metal Cutting ◽  
Chip Separation ◽  
Chip Geometry

A finite element model of orthogonal metal cutting is described. The paper introduces a new chip separation criterion based on the effective plastic strain in the workpiece. Several cutting parameters that are often neglected in simplified metal-cutting models are included, such as elastic-plastic material properties of both the workpiece and tool, friction along the tool rake face, and geometry of the cutting edge and workpiece. The model predicts chip geometry, residual stresses in the workpiece, and tool stresses and forces, without any reliance on empirical metal cutting data. The paper demonstrates that use of a chip separation criterion based on effective plastic strain is essential in predicting chip geometry and residual stresses with the finite element method.

Water Vapor Cooling Effects in Turning by Finite Element Modeling

2011 ◽  
Vol 189-193 ◽  
pp. 1631-1634
Author(s):  
Fan Yang ◽  
Jian Long Huang
Keyword(s):  
Finite Element ◽  
Water Vapor ◽  
Geometric Modeling ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Fem Simulation ◽  
Cutting Process ◽  
Finite Element Software ◽  
Aisi 1045 ◽  
Cooling Effects

In order to correctly analyze the effect of water vapor cooling in metal cutting process, the turning process of AISI 1045 in the water vapor cooling condition is simulated using a commercial finite element software Deform-2D, including geometric modeling, meshing, boundary condition setting and material modeling, etc. The cutting temperature in different cooling conditions are then analyzed and discussed. The experimental validation showed a good agreement with simulation results. Thus, FEM simulation of cutting process can be considered as a promising and reliable tool for machining development within the near future.

scholarly journals FINITE ELEMENT MODELING OF THE CUTTING PROCESS DURING MACHINING OF STRUCTURAL STEEL USING ANSYS WORKBENCH

2019 ◽  
pp. 121-127
Author(s):  
М. Кхалифа ◽  
M. Khalifa ◽  
Т. Дуюн ◽  
T. Duyun
Keyword(s):  
Finite Element ◽  
Structural Steel ◽  
Metal Cutting ◽  
Kinematic Hardening ◽  
Cutting Process ◽  
Traditional Theory ◽  
Deformation And Failure ◽  
Commercial Code ◽  
Formation Conditions ◽  
Ansys Workbench

The technique of modeling the cutting process when sharpening structural steel (steel 45) is presented. The 3D finite element simulations of machining are conducted using commercial code ANSYS Workbench. For the simulation of plastic deformation and failure of the materials, a Johnson-Cook model is used as constitutive equation to describe behavior of material during cutting process. This model takes into account the effects of the kinematic hardening and adiabatic heating of the deformable material. To model separation of chip from the workpiece, the Johnson–Cook (J–C) damage criterion is used. In the suggested model, the value of feed is taken into account as the width of the strip of the workpiece for modeling workpiece. As a result of modeling, the stress and strain fields for both the workpiece and the tool are presented, as well as the thermal field of the chip and the machined piece. The results are compared and evaluated with the experimental results; they are similar and do not contradict the traditional theory of the metal cutting. The proposed method of modeling allows to study the stress-strain state and thermal distributions of the cutting process, chip formation conditions and prediction of the quality of finished surface.

Research and Application of Finite Element Method on the Simulation of Graded Self-Lubricating Ceramic Tools

2013 ◽  
Vol 712-715 ◽  
pp. 683-687
Author(s):  
Chun Lin Wang ◽  
Chong Hai Xu ◽  
Xiu Guo Xu
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Metal Cutting ◽  
Cutting Process ◽  
Ceramic Tool ◽  
Tool Materials ◽  
Ceramic Tools ◽  
Theory Research ◽  
Element Method

The introduction and application of common finite element method (FEM) about the modern metal cutting theory research was stated emphatically. Graded self-lubricating ceramic tool materials was briefly introduced, and problems existed about simulating the metal cutting process using FEM are pointed out and discussed in this study.

Analysis of the Influence of Cutting Parameters on Cutting Force Based on Cutting Process Simulation

2013 ◽  
Vol 710 ◽  
pp. 223-227
Author(s):  
Yan Cao ◽  
Hua Chen ◽  
Hai Xia Zhao
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Cutting Force ◽  
Process Simulation ◽  
Metal Cutting ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Rigid Plastic ◽  
Simulation Parameters ◽  
Element Method

Based on the study on metal cutting theories and rigid-plastic finite element method, taking Sweden SECO lathe tool MDT as the researching object, the cutting force in cutting process is analyzed after a cutting process simulation model is constructed using finite element method. Different simulation parameters and cutting parameters are used to carry out analyses time after time. The dynamic changing curves of the cutting force in cutting process are obtained. Through the comparison of the cutting force in different cutting conditions, the influence of cutting parameters on the cutting force is summarized. The research can provide useful data for improvement of metal cutting technology and tool cutting performance.

Simulation Research on the Metal Cutting Process

2013 ◽  
Vol 641-642 ◽  
pp. 277-280
Author(s):  
Cheng Lei ◽  
Shou Ne Xiao ◽  
Shi Hui Luo
Keyword(s):  
Finite Element ◽  
Metal Cutting ◽  
Three Dimensional ◽  
Element Model ◽  
Rake Angle ◽  
Friction Model ◽  
Cutting Process ◽  
Simulation Research ◽  
Finite Element Software ◽  
Explicit Analysis

The three-dimensional explicit dynamic analysis of metal cutting process is done using the non- linear finite element software LS-DYNA. In the finite element model, 8- node 3D solid element based on one- point integration Lagrangian formulation is adopted, metal material is modeled with Johnson-Cook constitutive model, chip separation is simulated using the material failure criterion of Johnson and Cook proposed and combing the failure element deletion method, friction model of chip-tool contact interface is developed to simultaneously account for sticking and sliding situation. Through explicit analysis, rake angle, cutting depth, and cutting width on the shape of the chip influence are obtained.

scholarly journals Heat partition effect on cutting tool morphology in orthogonal metal cutting using finite element method

Mechanika ◽  
2019 ◽  
Vol 25 (4) ◽  
pp. 326-334
Author(s):  
Kamuran Kamil YEŞİLKAYA ◽  
Kemal YAMAN
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Temperature Distribution ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Thermal Analyses ◽  
Cutting Process ◽  
Heat Partition ◽  
Coated Tools ◽  
Element Method

It is widely accepted that heat partition and temperature distribution for metal cutting process have a significant effect on the morphological features of the cutting tool. Tool life and cutting accuracy are considerably affected by temperature distribution and heat transfer mechanisms on the tool. When a finite elements model is accurately generated, an understanding of heat partition into the cutting tool without performing experiments can be gained. This study has been completed with the use of uncoated and coated tools in order to predetermine heat partition value entering the cutting tool. In terms of coated tools, tool coating was investigated to assess its effects on heat partition. Finite Element Method was mainly used in combination with the previously generated experimental data in literature. Three-dimensional uncoated and coated models were created and made compatible with finite element modeling software to be able to perform thermal analyses of the cutting process. Finite element transient and steady-state temperature values were calculated and hence the heat intensity value for the cutting tool was determined.

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.

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