Application of FEM simulation of chip formation to stability analysis in orthogonal cutting process

Nowadays, numerical simulation technique is very popular to estimate and predict the machining parameters such as cutting forces, stresses distribution, temperature and tool wear. The objective of this study is to determine the 0.45%C steel (JIS S45C) flow stress value under high strain rate and temperature. The Johnson and Cook (JC) material model is used as a constitutive equation to describe the high speed cutting process. Compression test and orthogonal cutting test were carried out in order to obtain the required parameters in JC model. Inverse calculation method was used to determine the strain rate and temperature dependency parameter based on several cutting conditions. As a result, validity of verification of method was completed and the flow stress of S45C had been evaluated.

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Application of the Nodal Integrated Finite Element Method to Cutting: a Preliminary Comparison with the “Traditional” FEM Approach

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.223.172 ◽

2011 ◽

Vol 223 ◽

pp. 172-181 ◽

Cited By ~ 3

Author(s):

Francesco Greco ◽

Domenico Umbrello ◽

Serena Di Renzo ◽

Luigino Filice ◽

I. Alfaro ◽

...

Keyword(s):

Finite Element Method ◽

Finite Element ◽

Large Deformation ◽

Orthogonal Cutting ◽

Fem Simulation ◽

Cutting Process ◽

Integration Technique ◽

Mesh Distortion ◽

Nodal Integration ◽

Element Method

FEM implicit formulation shows specific limitations in processes such as cutting, where large deformation results in a heavy mesh distortion. Powerful rezoning-remeshing algorithms strongly reduce the effects of such a limitation but the computational times are significantly increased and additional errors are introduced. Nodal Integration is a recently introduced technique that allows finite element method to provide more reliable results when mesh becomes distorted in traditional FEMs. Furthermore, volumetric locking phenomenon seems to be avoided by using this integration technique instead of other methods, such as the coupled formulations. In this paper, a comparison between a “classical” FEM simulation and the Nodal Integration one is carried out taking into account a simple orthogonal cutting process.

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A FEM and Experimental Study of Chip Formation in Orthogonal Cutting of Superalloy GH80A

Materials Science Forum ◽

10.4028/www.scientific.net/msf.626-627.663 ◽

2009 ◽

Vol 626-627 ◽

pp. 663-668

Author(s):

Jun Li Li ◽

Ming Chen ◽

Bin Rong

Keyword(s):

Chip Formation ◽

Orthogonal Cutting ◽

Cutting Temperature ◽

Chip Morphology ◽

Rake Angle ◽

Cutting Process ◽

High Yield ◽

Isotropic Model ◽

On Chip ◽

As Stress

The nickel-based superalloy GH80A has been widely used in kinds of aeronautical key structures because of its high yield stress and anti-fatigue performance at high temperature. However, it is also a typical difficult-to-cut material. In order to improve cutting process, kinds of methods have been applied to study cutting process including experimental approach and finite element method (FEM). In this paper, a comparison of chip formation is carried out between traditional Johnson-Cook (JC) model and Isotropic model. Besides, effects of tool rake angle and friction coefficient on chip formation are investigated by Isotropic model. FEM predicated results such as stress and cutting temperature are also analyzed. Relative turning tests are performed and comparison of chip morphology between FEM and experiment is carried out.

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Mechanisms and FEM Simulation of Chip Formation in Orthogonal Cutting In-Situ TiB2/7050Al MMC

Materials ◽

10.3390/ma11040606 ◽

2018 ◽

Vol 11 (4) ◽

pp. 606 ◽

Cited By ~ 9

Author(s):

◽

Keyword(s):

Chip Formation ◽

Orthogonal Cutting ◽

Fem Simulation

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Influences of Cutting Speed and Material Constitutive Models on Chip Formation and their Effects on the Results of Ti6Al4V Orthogonal Cutting Simulation

10.25518/esaform21.2424 ◽

2021 ◽

Author(s):

Nithyaraaj Kugalur-Palanisamy ◽

Edouard Rivière-Lorphèvre ◽

Pedro-José Arrazola ◽

François Ducobu

Keyword(s):

Finite Element ◽

Constitutive Model ◽

Chip Formation ◽

Orthogonal Cutting ◽

Constitutive Models ◽

Cutting Speed ◽

Element Model ◽

Cutting Process ◽

Machine Material ◽

On Chip

The highly used Ti6Al4V alloy is a well know hard-to-machine material. The modelling of orthogonal cutting process of Ti6Al4V attract the interest of many researchers as it often generates serrated chips. The purpose of this paper is to show the significant influence of cutting speed on chip formation during orthogonal cutting of Ti6Al4V along with different material constitutive models. Finite element analyses for chip formation are conducted for different cutting speeds and are investigated with well-known Johnson-Cook constitutive model, a modified Johnson–Cook model known as Hyperbolic Tangent (TANH) model that emphasizes the strain softening behavior and modified Johnson-Cook constitutive model that consider temperature dependent strain hardening factor. A 2D Lagrangian finite element model is adopted for the simulation of the orthogonal cutting process and the results from the simulations such as calculated forces, chip morphologies are analyzed and are compared with the experimental results to highlight the differences. The results analysis shows that, the temperature in the secondary deformation zone is directly proportional to the cutting speed.

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Effects of Tool Geometrical Parameters on the Chip Formation and Cutting Force in Orthogonal Cutting

Materials Science Forum ◽

10.4028/www.scientific.net/msf.471-472.16 ◽

2004 ◽

Vol 471-472 ◽

pp. 16-20 ◽

Cited By ~ 3

Author(s):

Gang Fang ◽

P. Zeng

Keyword(s):

Cutting Force ◽

Chip Formation ◽

Coupling Effect ◽

Orthogonal Cutting ◽

Rake Angle ◽

Cutting Process ◽

Geometrical Parameters ◽

Actual Process ◽

Mechanical Coupling ◽

Chip Separation

The tool plays an important role in cutting process. The aim of this paper is to investigate the effect of tool geometrical parameters on the chip formation and cutting force with orthogonal cutting models. The large deformation Rigid-visco-plastic FEM program DEFORM-2DTM is used, and thermo-mechanical coupling effect are considered. The chip separation from workpiece is implemented by remeshing. Contrary to traditional cutting simulation, the workpiece is moved and the tool is fixed, which is consistent with actual process. The effects of tool rake angle on the chip geometry and cutting force are analyzed. The simulated cutting forces are compared with results in other references. The research results are a help to cutting process study and cutting tool design.

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Machining FEM Model of Unidirectional Carbon Fiber Reinforced Laminate

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.601.105 ◽

2012 ◽

Vol 601 ◽

pp. 105-109

Author(s):

Jing Yi Wang ◽

Yan Li He ◽

Xu Wang

Keyword(s):

Finite Element ◽

Cutting Force ◽

Chip Formation ◽

Orthogonal Cutting ◽

Surface Damage ◽

Cutting Process ◽

Fe Model ◽

Cfrp Laminate ◽

Finite Element Software ◽

Chip Formation Mechanism

A two-dimensional macro-mechanical finite element (FE) model is developed to study the orthogonal cutting process of CFRP unidirectional laminate by the finite element software ABAQUS. The CFRP laminate is defined as an equivalent orthotropic, homogeneous single-phase material. On the basis of composite unidirectional laminate plane stress-strain and strength theory, the author adopts Hashin progressive damage criteria in the FE model. Based on the results of finite element simulation, the changes of cutting force in the chip formation process of CFRP laminate are analyzed, the Hashin damage in the cutting process and the influences of fiber orientation on cutting force, chip formation mechanism and sub-surface damage are explored as well. The comparison between this paper and previous related research shows that the results have a reasonable agreement with the previous achievements.

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3D FEM Simulation of Micro Cutting for Prism Patterning on Nickel Plated Roll Die Using Lagrangian Method

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.516.170 ◽

2012 ◽

Vol 516 ◽

pp. 170-175

Author(s):

Kyung Hee Park ◽

Dong Yoon Lee ◽

Ki Hyeong Song ◽

Seok Woo Lee

Keyword(s):

Chip Formation ◽

Cutting Forces ◽

Cutting Tool ◽

Orthogonal Cutting ◽

Fem Simulation ◽

Fe Model ◽

3D Fem ◽

Micro Cutting ◽

Edge Wear ◽

Good Agreement

An FE model can be usedfor better understanding the micro cutting process. To identify an edge wear effect, the cutting forces and contact stress on the cutting tool were measured as edge wear progress. On the other hand, a series of orthogonal cutting tests was also carried out forcomparisonwith FEM simulation results in termsof chip formation and cutting forces. A scanning electron microscope (SEM) was used to observe the tools and chips for the purpose of taking measurements. A Kistler dynamometer was also utilized for cutting forces measurement. The FEM micro cutting simulation showed good agreement with experimentalresults in terms of the cutting forces and chip formation. And it was observed in both FEM simulations and experiments that larger edge wear caused higher cutting forces.

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

Volume 1: Advanced Computational Mechanics; Advanced Simulation-Based Engineering Sciences; Virtual and Augmented Reality; Applied Solid Mechanics and Material Processing; Dynamical Systems and Control ◽

10.1115/esda2012-82900 ◽

2012 ◽

Cited By ~ 3

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.

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