From Orthogonal Cutting Experiments towards Easy-to-Implement and Accurate Flow Stress Data

2013 ◽  
Vol 28 (11) ◽  
pp. 1222-1227 ◽  
Author(s):  
F. Klocke ◽  
D. Lung ◽  
S. Buchkremer ◽  
I. S. Jawahir
Keyword(s):  
Flow Stress ◽  
Orthogonal Cutting ◽  
Flow Stress Data ◽  
Cutting Experiments

The Effect of Material Flow Stress on Analytical Simulation of Machining

2010 ◽  
Vol 29-32 ◽  
pp. 1809-1814
Author(s):  
Bing Lin Li ◽  
Ling Ling ◽  
Yu Jin Hu ◽  
Xue Lin Wang
Keyword(s):  
Flow Stress ◽  
Shear Zone ◽  
Analytical Model ◽  
Material Flow ◽  
Model Simulation ◽  
Orthogonal Cutting ◽  
Shear Plane ◽  
Thermomechanical Model ◽  
Workpiece Material ◽  
Flow Stress Data

The flow stress data of the workpiece are extremely crucial for the cutting simulation. The study shows how the input data affect the analytical predictions of cutting force and temperature. The Johnson-Cook material model is used to represent workpiece flow stress in the primary shear zone. A thermomechanical model of orthogonal cutting is proposed based on the main shear plane divides the primary shear zone into two unequal parts. Five different sets of workpiece material flow stress data used in the Johnson-Cook’s constitutive equation are chosen and make the sensitivity analysis for analytical model. Simulation results were compared to orthogonal cutting test data from the available literature, and find the effects of flow stress on analytical model was different from that for finite element model.

Cutting Experiments in Cutting Speeds of up to 200 m/s with a High-Speed Impact Cutting Tester

2012 ◽  
Vol 523-524 ◽  
pp. 1041-1046 ◽  
Author(s):  
Tappei Higashi ◽  
Masato Sando ◽  
Jun Shinozuka
Keyword(s):  
High Speed ◽  
Ambient Pressure ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
High Speed Impact ◽  
Air Gun ◽  
Impact Cutting ◽  
Compressed Gas ◽  
Cutting Experiments ◽  
Cutting Speeds

High-speed orthogonal cutting experiments with cutting speeds of up to 200 m/s with a high-speed impact cutting tester of air-gun type are attempted. In this tester, a light projectile with a small built-in cutting tool is loaded into a tube, being accelerated by a compressed gas. The projectile captures the chip that is indispensable to analyze the cutting mechanism. The projectile holding the chip is decelerated by another compressed gas just after finishing the cutting, being stopped without damage in the tube. Successful experiment can be accomplished by setting adequate values of the operation parameters for the experiment, which are the pressure of each gas and the opening and shutting time of the solenoid-controlled valve for each compressed gas. In order to determine the adequate values of these parameters, a ballistic simulator that simulates the velocity and position of the projectile traveling in the tube is developed. By setting the values of these parameters obtained by the simulator, the cutting speed of 200 m/s is achieved when the ambient pressure is set to be a vacuum and helium is used for each compressed gas. This paper describes the ballistic simulator developed and shows the experimental results of the high-speed cutting of aluminum alloy A2017.

Prediction of Adiabatic Shear Critical Cutting Conditions of hardened AISI 1045 Steel with Different Hardness

2013 ◽  
Vol 589-590 ◽  
pp. 134-139
Author(s):  
Guo He Li ◽  
Yu Jun Cai ◽  
Hou Jun Qi
Keyword(s):  
Model Building ◽  
Orthogonal Cutting ◽  
Adiabatic Shear ◽  
Cutting Conditions ◽  
Constitutive Relationship ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Relationship Of ◽  
1045 Steel ◽  
Cutting Experiments

A method for building the constitutive relationship based on the J-C model and hardness is presented through considering the influence of hardness on the yield strength and the tensile strength. A constitutive relationship of hardened AISI 1045 is built by this method and the adiabatic shear critical cutting conditions of three kinds of hardness AISI 1045 steel are prediction through a model building by the linear pertubation analysis which considering the influence of compression stress of the primary shear zone, the cutting conditions and the constitutive relationship. For proving the prediction results, some orthogonal cutting experiments are performed to get the critical cutting conditions of adiabatic shear. The comparison shows that the prediction results are consistent with that of experiments.

Two Methods for the Constitutive Modeling of TiB2/7050 Al Composites

2019 ◽  
Author(s):  
Kunyang Lin ◽  
Wenhu Wang ◽  
Ruisong Jiang ◽  
Xiaofen Liu ◽  
Xiaoxiang Zhu ◽  
...  
Keyword(s):  
Constitutive Model ◽  
Orthogonal Cutting ◽  
Absolute Error ◽  
Strain Rate Range ◽  
Matrix Composites ◽  
Statistical Parameters ◽  
Strain Behavior ◽  
Cutting Experiments ◽  
Jc Model

Abstract In this paper, the Johnson-Cook constitutive model of in situ TiB2/7050 Al metal matrix composites determined by two different methods are compared. The commonly used quasi-static and dynamic compressive experiments are firstly conducted under the strain rate range of 10−3∼5000s−1 and temperature range of 20∼200 °C. The orthogonal cutting experiments are also used to calculate the JC model. The description ability of two models are evaluated by two statistical parameters: correlation coefficient and average absolute error. The results show that the JC model determined by the compression experiments performs better to describe the stress-strain behavior of in situ TiB2/7050 Al composites. Although the JC model from orthogonal cutting experiments can be used to simulate the cutting process, it cannot describe the flow stress behavior exactly during material deformation processes. For an accurate constitutive model of a material, the basic tensile or compression test is deemed necessary.

Flow Stress Experimental Determination for Warm-Forming Process

2011 ◽  
Author(s):  
Ting Fai Kong ◽  
Luen Chow Chan ◽  
Tai Chiu Lee
Keyword(s):  
Stainless Steel ◽  
Flow Stress ◽  
Room Temperature ◽  
Warm Forming ◽  
Recrystallization Temperature ◽  
Process Conditions ◽  
Compression Tests ◽  
Forming Process ◽  
Forming Temperature ◽  
Flow Stress Data

Warm forming is a manufacturing process in which a workpiece is formed into a desired shape at a temperature range between room temperature and material recrystallization temperature. Flow stress is expressed as a function of the strain, strain rate, and temperature. Based on such information, engineers can predict deformation behavior of material in the process. The majority of existing studies on flow stress mainly focus on the deformation and microstructure of alloys at temperature higher than their recrystallization temperatures or at room temperature. Not much works have been presented on flow stress at warm-forming temperatures. This study aimed to determine the flow stress of stainless steel AISI 316L and titanium TA2 using specially modified equipment. Comparing with the conventional method, the equipment developed for uniaxial compression tests has be verified to be an economical and feasible solution to accurately obtain flow stress data at warm-forming temperatures. With average strain rates of 0.01, 0.1, and 1 /s, the stainless steel was tested at degree 600, 650, 700, 750, and 800 °C and the titanium was tested at 500, 550, 600, 650, and 700 °C. Both materials softened at increasing temperatures. The overall flow stress of stainless steel was approximately 40 % more sensitive to the temperature compared to that of titanium. In order to increase the efficiency of forming process, it was suggested that the stainless steel should be formed at a higher warm-forming temperature, i.e. 800 °C. These findings are a practical reference that enables the industry to evaluate various process conditions in warm-forming without going through expensive and time consuming tests.

scholarly journals Analysis of critical negative rake angle and friction characteristics in orthogonal cutting of AL1060 and T2

2019 ◽  
Vol 103 (1) ◽  
pp. 003685041987806 ◽  
Author(s):  
Yanchun Ding ◽  
Guangfeng Shi ◽  
Hua Zhang ◽  
Guoquan Shi ◽  
Dongdong Han
Keyword(s):  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Cutting Tools ◽  
Flow Characteristics ◽  
Rake Angle ◽  
Machined Surface ◽  
Friction Characteristics ◽  
Model Based ◽  
Stagnant Region ◽  
Cutting Experiments

The stagnant region often appears in front of the tool cutting edge, which is caused by mechanical inlay and excessive pressing in plastic metal cutting with large negative rake angle tools at a low speed. It results in the change of the effective negative rake angle which can affect the flow characteristics of material, the quality of machined surface and the abrasion loss of cutting tools. However, the critical negative rake angle model based on the existence of the stagnant region has not been reported yet. Therefore, in order to investigate the critical negative rake angle value considering the stagnant region, a critical negative rake angle model based on the principle of minimum required energy is established, and the correctness of the theoretical model is verified by orthogonal cutting experiments. At the same time, the influence of the critical value of the large negative rake angle tool on the machined surface quality is studied through different cutting experiments. These experimental results show that the deviations of both experimental and theoretical critical negative rake angle are less than 5% during the orthogonally cutting of the aluminium (AL1060) and copper (T2) materials by the negative rake angle tool. Meanwhile, the critical negative rake angle is related to the adhesive friction coefficient of tool–workpiece contact surface. The analysis of friction characteristics shows that the deviation values of both theoretical and experimental critical negative rake angle are proportional to the coefficient of adhesive friction and the thickness of the stagnant region. Critical negative rake angle has a significant effect on roughness and residual stress of the machined surface.

scholarly journals Comparison of Flow Stress of Aluminum Alloy 6061-T6 Obtained From Chip Pulling Orthogonal Cutting and Kolsky Bar Testing

2020 ◽  
Vol 48 ◽  
pp. 579-585
Author(s):  
Changlong Cui ◽  
Pavan Bhavsar ◽  
Homar Lopez-Hawa ◽  
Vis Madhavan ◽  
Wilfredo Moscoso-Kingsley
Keyword(s):  
Aluminum Alloy ◽  
Flow Stress ◽  
Orthogonal Cutting ◽  
Kolsky Bar ◽  
Aluminum Alloy 6061 ◽  
Alloy 6061

A Methodology to Determine Work Material Flow Stress and Tool-Chip Interfacial Friction Properties by Using Analysis of Machining

2004 ◽  
Author(s):  
Tug˘rul O¨zel ◽  
Erol Zeren
Keyword(s):  
Flow Stress ◽  
Material Flow ◽  
Orthogonal Cutting ◽  
Material Model ◽  
Interfacial Friction ◽  
Frictional Stress ◽  
Rake Face ◽  
Friction Characteristics ◽  
Work Material ◽  
1045 Steel

In this paper, we develop a methodology to determine flow stress at the machining regimes and friction characteristics at the tool-chip interface from the results of orthogonal cutting tests. We utilize metal cutting analysis originally developed by late Oxley and present some improvements. We also evaluate several temperature models in calculating the average temperatures at primary and secondary deformation zones and present comparisons with the experimental data obtained for AISI 1045 steel through assessment of machining models (AMM) activity. The proposed methodology utilizes measured forces and chip thickness obtained through a basic orthogonal cutting test. We conveniently determine work material flow stress at the primary deformation zone and the interfacial friction characteristics along tool rake face. Calculated friction characteristics include parameters of the normal and frictional stress distributions on the rake face. Determined flow stress data from orthogonal cutting tests is combined with the flow stress measured through split-hopkinson pressure bar (SHPB) tests and the Johnson-Cook work material model is obtained. Therefore, with this methodology, we extend the applicability of Johnson-Cook work material model to machining regimes.

Simulation of Deform Behavior of WE43 Magnesium Alloy Based on DEFORM-3D

2009 ◽  
Vol 618-619 ◽  
pp. 191-194 ◽  
Author(s):  
Qiang Wang ◽  
Jia Cheng Gao ◽  
Wen Juan Niu
Keyword(s):  
Flow Stress ◽  
Magnesium Alloy ◽  
Computational Simulation ◽  
Forming Process ◽  
Actual Operation ◽  
Actual Flow ◽  
Flow Stress Data ◽  
The Cost ◽  
Deform 3D ◽  
We43 Magnesium Alloy

Compared with the actual operation, computational simulation will save the cost and provide more valuable references or guiding significance for the real production. Using professional forming software DEFORM-3D, the upsetting process of WE43 magnesium alloy was simulated. Based on the actual flow stress data, the simulation model of WE43 magnesium alloy was created in DEFORM-3D. Results show that the uniform distribution of the temperature of WE43 magnesium alloy during the forming process is beneficial to the structural homogeneity and contributes to excellent flowing property. There is the stress concentration in the edge and slide face of the billet. So during the process of compression, the fracture will appear earlier in the edge and slide face of the sample.

Sign in / Sign up

Export Citation Format

Share Document