Inverse identification of flow stress in metal cutting process using Response Surface Methodology

2016 ◽  
Vol 60 ◽  
pp. 40-53 ◽  
Author(s):  
Amir Malakizadi ◽  
Stefan Cedergren ◽  
Ibrahim Sadik ◽  
Lars Nyborg
Keyword(s):  
Response Surface Methodology ◽  
Flow Stress ◽  
Response Surface ◽  
Metal Cutting ◽  
Cutting Process ◽  
Inverse Identification

scholarly journals Application of response surface methodology and fuzzy logic based system for determining metal cutting temperature

2016 ◽  
Vol 64 (2) ◽  
pp. 435-445 ◽  
Author(s):  
D. Tanikić ◽  
V. Marinković ◽  
M. Manić ◽  
G. Devedžić ◽  
S. Ranđelović
Keyword(s):  
Response Surface Methodology ◽  
Fuzzy Logic ◽  
Response Surface ◽  
Metal Cutting ◽  
Single Point ◽  
Cutting Temperature ◽  
Cutting Speed ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Cutting Regimes

Abstract The heat produced in metal cutting process has negative influence on the cutting tool and the machined part in many aspects. This paper deals with measurement of cutting temperature during single-point dry machining of the AISI 4140 steel, using an infrared camera. Various combinations of cutting parameters, i.e. cutting speed, feed rate and depth of cut lead to different values of the measured cutting temperature. Analysis of the measured data should explain the trends in temperature changes depending on changes in the cutting regimes. Furthermore, the temperature data is modelled using response surface methodology and fuzzy logic. The models obtained should determine the influence of cutting regimes on cutting temperature. The main objective is the reduction of cutting temperature, i.e. enabling metal cutting process in optimum conditions.

An Integral Method to Determine Workpiece Flow Stress and Friction Characteristics in Metal Cutting

2015 ◽  
Vol 9 (6) ◽  
pp. 775-781
Author(s):  
Norfariza Wahab ◽  
◽  
Yumi Inatsugu ◽  
Satoshi Kubota ◽  
Soo-Young Kim ◽  
...  
Keyword(s):  
Flow Stress ◽  
Strain Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Edge ◽  
Cutting Process ◽  
Machining Parameters ◽  
Friction Characteristics ◽  
High Speed Cutting

In recent times, numerical simulation techniques have been commonly used to estimate and predict machining parameters such as cutting forces, stresses, and temperature distribution. However, it is very difficult to estimate the flow stress of a workpiece and the friction characteristics at a tool/chip interface, particularly during a high-speed cutting process. The objective of this study is to improve the accuracy of the present method and simultaneously determine the characteristics of the flow stress of a workpiece and friction at the cutting edge under a high strain rate and temperature during the cutting process. In this study, the Johnson-Cook (JC) flow stress model is used as a function of strain, strain rate, and temperature. The friction characteristic was estimated by minimizing the difference between the predicted and measured results of principal force, thrust force, and shear angle. The shear friction equation was used to estimate the friction characteristics. Therefore, by comparing the measured values of the cutting forces with the predicted results from FEM simulations, an expression for workpiece flow stress and friction characteristics at the cutting edge during a high-speed cutting process was estimated.

Inverse Identification of Material Parameters of Titanium Alloy TB5 Based on Response Surface Methodology and Quasi-Newton Method

2012 ◽  
Vol 482-484 ◽  
pp. 2012-2016 ◽  
Author(s):  
Yong Na Sun ◽  
Min Wan ◽  
Xiang Dong Wu
Keyword(s):  
Response Surface Methodology ◽  
Titanium Alloy ◽  
Response Surface ◽  
Newton Method ◽  
Uniform Design ◽  
Element Model ◽  
Tensile Tests ◽  
Alloy Sheet ◽  
Inverse Identification ◽  
Quasi Newton

The anisotropic behavior of titanium alloy sheet TB5 cannot be accurately obtained by experimental identification of standard sheet uniaxile tensile tests. This paper describes a powerful technique allows for the identification of Hill’48 anisotropic parameters by inverse technique method based on the response surface methodology and quasi-Newton method. The identification approach takes the cylinder drawing as study object, and anisotropic parameters as optimum parameters. And the anisotropic parameters, which gained directly from experimental orthogonal test and uniform design tests, are tuned in the finite element model, that the numerically computed height and thickness of the cup matches the experimentally measured field as closely as possible. The result shows that the anisotropic parameters from the inverse identification can describe the mechanical behavior well.

Study on Constitutive Model of 20CrMnTi Gear Steel in Cutting Process

2011 ◽  
Vol 291-294 ◽  
pp. 311-317 ◽  
Author(s):  
Gan Hua Liu ◽  
Hong Zhi Yan
Keyword(s):  
Flow Stress ◽  
Constitutive Model ◽  
Metal Cutting ◽  
Cutting Process ◽  
Comprehensive Method ◽  
Model Flow ◽  
Gear Steel ◽  
Cutting Deformation ◽  
Flow Stress Data ◽  
Gear Steels

Flow stress data is important base data in using the analytical method and the finite element method to analyze the metal cutting process.In the present study, a comprehensive method combining with four methods of material mechanics tests, SHTB impact tests, two-dimensional orthogonal slot milling experiments and reverse solving is used to determine constitutive model (flow stress model) as a function of the "three-high" (high strain , temperature and strain rate) in metal cutting. The constitutive model of 20CrMnTi gear steel (hardened to170±5HB) which is one of China’s main gear steels in cutting deformation is established by using this method, and experimental results show that the model’s accuracy is high. Practice has proved that the methodology of constitutive model determination for metal cutting deformation, proposed in the present study, has advantages when compared with using one method alone, and is more suitable to establish flow data for the various materials in the metal cutting process.

scholarly journals Optimization of Cutting Parameters on Turning Process Based on Surface Roughness Using Response Surface Methodology

2011 ◽  
Vol 117-119 ◽  
pp. 1561-1565
Author(s):  
Muhammad Yusuf ◽  
Mohd Khairol Anuar Ariffin ◽  
N. Ismail ◽  
S. Sulaiman
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Cutting Condition ◽  
Dry Cutting ◽  
Optimization Of Cutting Parameters

This paper describes effect of cutting parameters on surface roughness for turning of aluminium alloy 7050 using carbide cutting tool with dry cutting condition. The model is developed based on cutting speed, feed rate and depth of cut as the parameters of cutting process. The selection of cutting process was based on the design of experiments Response Surface Methodology (RSM). The objective of this research is finding the optimum cutting parameters based on surface roughness. The relation between cutting parameters and surface roughness were discussed.

Parametric Optimization in Drilling Operation Using Response Surface Approach

2016 ◽  
Vol 1137 ◽  
pp. 117-131
Author(s):  
Kamaljit Singh Boparai ◽  
Sandeep Singh ◽  
Amritpal Singh
Keyword(s):  
Surface Roughness ◽  
Response Surface Methodology ◽  
Response Surface ◽  
Process Parameters ◽  
Metal Cutting ◽  
Parametric Optimization ◽  
Machining Parameters ◽  
Surface Approach ◽  
Contour Plots ◽  
Cutting Processes

Modeling and optimization of machining parameters are the indispensable elements in modern metal cutting processes. The present study realize the interaction of drilling input process parameters such as spindle speed, feed rate and number of holes and their influence on the surface roughness, diameter and position of hole obtained in drilling of mild steel. The contour plots were generated to highlights the interaction of process parameters as well as their effect on responses. An empirical model of surface roughness, diameter and position of hole was developed using response surface methodology (RSM). The model fitted and measured values were quite close, which indicates that the developed models can be effectively used to predict the respective response. The process parameters are optimized using desirability-based approach response surface methodology.

Determination of Constitutive Equation Parameters for Orthogonal Cutting through Pressure Bar Tests and FEA Method

2012 ◽  
Vol 499 ◽  
pp. 56-61 ◽  
Author(s):  
B. Lan ◽  
Ping Fa Feng ◽  
Z.J. Wu ◽  
D.W. Yu
Keyword(s):  
Constitutive Equation ◽  
Metal Cutting ◽  
Split Hopkinson Pressure Bar ◽  
Orthogonal Cutting ◽  
Cutting Process ◽  
Inverse Identification ◽  
Hopkinson Pressure Bar ◽  
Element Analysis ◽  
Pressure Bar ◽  
Cutting Experiments

This paper proposes a method of determining the constitutive equation parameters of a Japanese type of alloy steel (SCM440H) for Finite Element Analysis (FEA) of orthogonal cutting, involving pressure bar experiments, orthogonal metal cutting experiments and FEA inverse identification. First, Split Hopkinson Pressure Bar (SHPB) experiments combined with Quasi-Static pressure tests were conducted, and after analyzing and processing the experimental data, one set of original constitutive constants was obtained; in the mean time, orthogonal cutting experiments were also performed to collect the cutting force data. Then the original constants were put into FEA software to simulate the cutting process. But comparison between the orthogonal cutting experimental and the simulation results revealed the inadequacy for the constants to predict cutting forces. To address this problem, an inverse identification method was employed to optimize the constants iteratively. And after a certain number of iterations, the ideal parameters for FEA of the orthogonal cutting process were finally determined.

Application of desirability function based response surface methodology (DRSM) for investigating the plasma arc cutting process of sailhard steel

2018 ◽  
Vol 15 (4) ◽  
pp. 505-512 ◽  
Author(s):  
Deepak Kumar Naik ◽  
Kalipada Maity
Keyword(s):  
Response Surface Methodology ◽  
Response Surface ◽  
Desirability Function ◽  
Cutting Process ◽  
Plasma Arc ◽  
Content Type ◽  
Plasma Arc Cutting ◽  
Machining Parameter ◽  
Desirability Index ◽  
Selection Of

Purpose Plasma arc cutting (PAC) is extensively applicable for cutting the materials in faster speed with better accuracy in different manufacturing industries. The cutting of sailhard steel plate plays a great challenge in plasma arc cutting process. Design/methodology/approach In this investigation, a special abrasion-resistant steel known as sailhard of 20 mm thickness plate has been cut by PAC machine. Cutting current, stand-off distance, cutting speed and gas pressure were selected as cutting parameters. The corresponding responses focused for this study are material removal rate, kerf and chamfer. L30 orthogonal array based on a central composite design (CCD) of response surface methodology (RSM) was used to design the run of the experiment. For predicting and modeling of optimal cutting conditions, a hybrid approach of desirability function-based response surface methodology (DRSM) was acquainted. Findings The result of this study determines that desirability index (DI) was affected significantly with the machining parameter as well as their interaction. A confirmation test was carried out to analyze the degree of effectiveness of DRSM technique. Originality/value In PAC, the selection of process parameters and effect of that parameter on the output responses is of greater value because of the selection of best cutting condition.

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