Extremely Low-Stress Triaxiality Tests in Calibration of Fracture Models in Metal-Cutting Simulation

2016 ◽  
Vol 47 (11) ◽  
pp. 5302-5312 ◽  
Author(s):  
František Šebek ◽  
Petr Kubík ◽  
Jindřich Petruška ◽  
Jiří Hůlka
Keyword(s):  
Metal Cutting ◽  
Stress Triaxiality ◽  
Cutting Simulation ◽  
Fracture Models

Forming limit analysis of Mg-2Zn-1.2Al-0.2Ca-0.2RE alloy sheet using ductile fracture models

2019 ◽  
Vol 29 (8) ◽  
pp. 1181-1198 ◽  
Author(s):  
Fei-Fan Li ◽  
Gang Fang ◽  
Ling-Yun Qian
Keyword(s):  
Magnesium Alloy ◽  
Ductile Fracture ◽  
Stress Triaxiality ◽  
Forming Limit Diagram ◽  
Alloy Sheet ◽  
Image Correlation ◽  
Forming Limit ◽  
Correlation Technique ◽  
Forming Limits ◽  
Fracture Models

This work was aimed to experimentally and theoretically investigate the formability of a new magnesium alloy sheet at room temperature. The fracture forming limit diagram was predicted by MMC3 and DF2014 models, where the non-linear strain path effect was taken into account by means of damage accumulation law. In order to obtain the instantaneous values of the stress triaxiality and the Lode parameter during the deformation process, strains tracked by digital image correlation technique were transformed into stresses based on the constitutive equations. The fracture forming limit diagram predicted by the fracture models was compared with the forming limits obtained by ball punch deformation tests. The prediction errors were evaluated by the accumulative damage values, which verified the advantages of ductile fracture models in predicting the forming limits of the magnesium alloy sheets.

scholarly journals Comparison of MMC and BW fracture models for constructing 3D ductile fracture envelope of AA6063 during cold forming

2020 ◽  
Author(s):  
Jianye Gao ◽  
Tao He ◽  
Yuanming Huo ◽  
Miao Song ◽  
Tingting Yao ◽  
...  
Keyword(s):  
Ductile Fracture ◽  
Damage Model ◽  
Stress Triaxiality ◽  
Compression Tests ◽  
Cold Forming ◽  
Tension Tests ◽  
Wide Range ◽  
Round Bar ◽  
Fracture Models ◽  
Fracture Envelope

Abstract The 3D ductile fracture envelopes of AA6063-T6 was developed to predict and prevent its fracture. Smooth round bar (SRB) tension tests were carried out to characterize the flow stress, and a series of experiments were conducted to characterize the ductile fracture firstly, such as notched round bar (NR) tension tests, compression tests and torsion tests. These tests cover a wide range of stress triaxiality (ST) and Lode parameter (LP) to calibrate the ductile fracture criterion. Plasticity modeling was performed, and the predicted results were compared with corresponding experimental data to verify the plasticity model after these experiments. Then the relationship between ductile fracture strain and ST with LP was constructed using the modified Mohr–Coulomb (MMC) model and Bai and Wierzbicki (BW) model to develop the 3D ductile fracture envelope. Finally, a new ductile damage model was proposed based on the 3D fracture envelope of AA6063. The final results show that the predicted results from the proposed ductile fracture model showed good agreement with experimental results.

The Simulation of the Influence of Honed Edge Radius on the Cutting Force and Torque in Drilling 42CrMo with K-Grade Carbide Drill Bit

2011 ◽  
Vol 130-134 ◽  
pp. 1779-1784
Author(s):  
Tao Wang ◽  
Ya Shi Ke ◽  
Yi Dan Zhou
Keyword(s):  
Cutting Force ◽  
Metal Cutting ◽  
Simulation Software ◽  
Cutting Edge ◽  
Drilling Process ◽  
Drill Bit ◽  
Cutting Simulation ◽  
Edge Radius

This paper uses a metal cutting simulation software AdvantEdge FEM as the platform, and simulates the drilling process of three different honed cutting edge K-Grade carbide drills. The aim is to study the influence of different magnitude of honed cutting edge on the the cutting force and torque. According to the simulation, the z-axis force and torque increase while the margin of the fluctuation decrease with the honed edge radius increase. In this paper, the z-axis force and torque reach the maximum and the margin of fluctuation in the smallest when using the honed edge radius of 0.10mm.

The Simulation of the Influence of Honed Edge Radius on the Maximum Temperature in Drilling 42CrMo with K-Grade Carbide Drill Bit

2011 ◽  
Vol 399-401 ◽  
pp. 1848-1851
Author(s):  
Yi Dan Zhou ◽  
Tao Wang
Keyword(s):  
Metal Cutting ◽  
Cutting Temperature ◽  
Simulation Software ◽  
Cutting Edge ◽  
Maximum Temperature ◽  
Drilling Process ◽  
Drill Bit ◽  
Cutting Simulation ◽  
Edge Radius

This paper uses a metal cutting simulation software AdvantEdge FEM as the platform, and simulates the drilling process of 42CrMo with three different honed cutting edge K-Grade carbide drills. The aim is to study the influence of different magnitude of honed cutting edge on the maximum temperature of cutting area. According to the simulation, the maximum temperature does not absolutely increase with the honed edge radius increase. The cutting temperature reaches maximum when the honed edge radius is 0.06mm in this paper, meanwhile the margin of fluctuation in the smallest.

Determination of flow stress for metal cutting simulation—a progress report

2004 ◽  
Vol 146 (1) ◽  
pp. 61-71 ◽  
Author(s):  
Partchapol Sartkulvanich ◽  
Frank Koppka ◽  
Taylan Altan
Keyword(s):  
Flow Stress ◽  
Metal Cutting ◽  
Progress Report ◽  
Cutting Simulation

Analyzing Fracture Behavior of Beam-Column Joints Using Micromechanical Fracture Models

2015 ◽  
Vol 744-746 ◽  
pp. 3-7
Author(s):  
Chen Zhang ◽  
Yu Ping Sun ◽  
Ju Tao Zhang ◽  
Yu Gu
Keyword(s):  
Finite Element ◽  
Plastic Strain ◽  
Fracture Behavior ◽  
Equivalent Plastic Strain ◽  
Stress Triaxiality ◽  
Bolted Connection ◽  
Finite Element Software ◽  
Maximum Value ◽  
Fracture Models ◽  
Welded Connection

The micromechanical fracture models were used to study the fracture behavior of the welded connection and welded-bolted connection joints. The Void Growth Model was implemented in commercial finite element software ABAQUS through the user-defined subroutines. The results predicted that cracks initiated at the edge of the welds and extended along the length and thickness of the welds. Comparing the effects of equivalent plastic strain and stress triaxiality for the fracture of the first failure element of both beam-to-column joints, we found that the equivalent plastic strain grew linearly as the loads increased and the weld of the lower flange generated cracks when the stress triaxiality increased at maximum value.

Evaluation of Ductile Fracture Models in Finite Element Simulation of Metal Cutting Processes

2013 ◽  
Vol 136 (1) ◽  
Author(s):  
Jian Liu ◽  
Yuanli Bai ◽  
Chengying Xu
Keyword(s):  
Finite Element ◽  
Ductile Fracture ◽  
Damage Evolution ◽  
Metal Cutting ◽  
Fracture Criterion ◽  
Orthogonal Cutting ◽  
Systematic Evaluation ◽  
Fe Model ◽  
Fracture Models ◽  
Cutting Processes

In this paper, a systematic evaluation of six ductile fracture models is conducted to identify the most suitable fracture criterion for metal cutting processes. Six fracture models are evaluated in this study, including constant fracture strain, Johnson-Cook, Johnson-Cook coupling criterion, Wilkins, modified Cockcroft-Latham, and Bao-Wierzbicki fracture criterion. By means of abaqus built-in commands and a user material subroutine (VUMAT), these fracture models are implemented into a finite element (FE) model of orthogonal cutting processes in abaqus/Explicit platform. The local parameters (stress, strain, fracture factor, and velocity fields) and global variables (chip morphology, cutting forces, temperature, shear angle, and machined surface integrity) are evaluated. The numerical simulation results are examined by comparing to experimental results of 2024-T3 aluminum alloy published in the open literature. Based on the results, it is found that damage evolution should be considered in cutting process FE simulation. Moreover, the B-W fracture model with consideration of rate dependency, temperature effect and damage evolution gives the best prediction of chip removal behavior of ductile metals.

Numerical analysis of Johnson-Cook damage model parameters effects on the cutting simulation of AISI 1045

2021 ◽  
Vol 16 ◽  
Author(s):  
Yong Sun ◽  
Guohe Li ◽  
Zhen He ◽  
Xiangcheng Kong
Keyword(s):  
Finite Element ◽  
Metal Cutting ◽  
Damage Model ◽  
Model Parameters ◽  
Cutting Simulation ◽  
Element Simulation ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Simulation Results ◽  
1045 Steel

Background: Failure model is the important basis for the research of material failure and fracture, and plays an important role in the finite element simulation of metal cutting. Johnson-Cook damage model is widely used to predict the failure of many materials. Its damage evolution is controlled by five parameters Objective: In order to decrease the cost of damage parameters identification and find out the damage parameters which have great influence on the simulation results. This work can provide an assistance in the optimization and selection of constitutive model parameters. Methods: Suitable Johnson-Cook damage model parameters, which can be used in the metal cutting simulation of AISI 1045 steel, are selected by comparing the simulation results and the experiments results. The cutting process of AISI 1045 steel is simulated by changing the Johnson-Cook damage parameters in the ABAQUS/Explicit. Results: The relevance of cutting force, feed force, cutting temperature, and deformation coefficient with five Johnson-Cook damage parameters are determined. Conclusion: The finite element simulation results show that the Johnson-Cook damage model parameters D2 and D3 have the biggest impact on the cutting simulation of AISI 1045 steel. Meanwhile, different Johnson-Cook damage parameters would take different changes to the simulation results

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