Finite Element Simulation of Cutting Temperature Field during High Speed Machining Hardened Steel Based on ABAQUS

For the high speed cutting process of hardened 45 steel (45HRC), a finite element simulation of cutting deformation, cutting force and cutting temperature is finished with the large general finite element software ABAQUS. Through the building of geometry model, material model and heat conduction model, also the determination of boundary conditions, separation rule and friction condition, a thermal mechanical coupling finite element model of high speed cutting for hardened 45 steel is built. The serrated chip, cutting force and cutting temperature can be predicted. The comparison of experiment and simulation shows the validity of the model. The influence of cutting parameters on cutting process is investigated by the simulation under different cutting depthes and rake angles. The results show that as the increase of rake angle, the segment degree, cutting force and cutting temperature decrease. But the segment degree, also the cutting force and cutting temperature increase with the increase of cutting depth. This study is useful for the selection of cutting parameters of hardened steel.

Download Full-text

The role of material model in the finite element simulation of high-speed machining of Ti6Al4V

Proceedings of the Institution of Mechanical Engineers Part C Journal of Mechanical Engineering Science ◽

10.1177/0954406215604877 ◽

2016 ◽

Vol 230 (17) ◽

pp. 2959-2967 ◽

Cited By ~ 1

Author(s):

Chong-Yang Gao ◽

Liang-Chi Zhang ◽

Peng-Hui Liu

Keyword(s):

Finite Element ◽

Finite Element Simulation ◽

High Speed ◽

Material Model ◽

Machining Process ◽

High Speed Machining ◽

Serrated Chip ◽

Finite Element Program ◽

Element Simulation ◽

Improved Model

This paper provides a comprehensive assessment on some commonly used thermo-viscoplastic constitutive models of metallic materials during severe plastic deformation at high-strain rates. An hcp model previously established by us was improved in this paper to enhance its predictability by incorporating the key saturation characteristic of strain hardening. A compensation-based stress-updating algorithm was also developed to introduce the new hcp model into a finite element program. The improved model with the developed algorithm was then applied in finite element simulation to investigate the high-speed machining of Ti6Al4V. It was found that by using different material models, the simulated results of cutting forces, serrated chip morphologies, and residual stresses can be different too and that the improved model proposed in this paper can be applied to simulate the titanium alloy machining process more reliably due to its physical basis when compared with some other empirical Johnson–Cook models.

Download Full-text

Finite Element Simulation and Experiment of Chip Formation during High Speed Cutting of Hardened Steel

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.29-32.1838 ◽

2010 ◽

Vol 29-32 ◽

pp. 1838-1843 ◽

Cited By ~ 5

Author(s):

Chun Zheng Duan ◽

Hai Yang Yu ◽

Yu Jun Cai ◽

Yuan Yuan Li

Keyword(s):

Finite Element ◽

Cutting Force ◽

High Speed ◽

Chip Morphology ◽

Hardened Steel ◽

High Speed Machining ◽

Serrated Chip ◽

High Speed Cutting ◽

Element Simulation ◽

Aisi 1045

As an advanced manufacturing technology which has been developed rapidly in recent years, high speed machining is widely applied in many industries. The chip formation during high speed machining is a complicated material deformation and removing process. In research area of high speed machining, the prediction of chip morphology is a hot and difficult topic. A finite element method based on the software ABAOUS which involves Johnson-Cook material model and fracture criterion was used to simulate the serrated chip morphology and cutting force during high speed cutting of AISI 1045 hardened steel. The serrated chip morphology and cutting force were observed and measured by high speed cutting experiment of AISI 1045 hardened steel. The effects of rake angle on cutting force, sawtooth degree and space between sawteeth were discussed. The investigation indicates that the simulation results are consistent with the experiments and this finite element simulation method presented can be used to predict the chip morphology and cutting force accurately during high speed cutting of hardened steel.

Download Full-text

Finite Element Simulation of High Speed Machining of Ti6Al4V Alloy and the Corresponding Experimental Study

Materials Science Forum ◽

10.4028/www.scientific.net/msf.836-837.444 ◽

2016 ◽

Vol 836-837 ◽

pp. 444-451 ◽

Cited By ~ 1

Author(s):

Long Hui Meng

Keyword(s):

Finite Element ◽

Constitutive Model ◽

Finite Element Simulation ◽

High Speed ◽

Split Hopkinson Pressure Bar ◽

Ti6al4v Alloy ◽

Machining Process ◽

High Speed Machining ◽

Hopkinson Pressure Bar ◽

Element Simulation

Finite element simulation of high speed machining of Ti6Al4V alloy was carried out based on the software of Abaqus. The Johnson-Cook constitutive model was chosen for the material of Ti6Al4V, the parameters of the model were obtained through the SHPB (Split Hopkinson Pressure Bar) experiment. The similarity of the chips obtained from the simulation and that obtained from the experiment indicated that the parameters of the Johnson-Cook constitutive model for Ti6Al4V alloy were reliable. Different cutting parameters and different tool geometric parameters were used in the simulations to find out their effects to the simulation results. Also a comparison was made between the results got form the simulations results and the experimental results, a good agreement between them indicated that the finite element simulation of high speed machining of Ti6Al4V is reliable, so it can be concluded that the finite element simulations of high speed machining can be widely used in practice to study the more about the machining process and reduce the experimental expenses.

Download Full-text

Research on Finite Element Simulation and Experiment of Temperature Field for Surface Cutting of Nanostructured WC/12Co Coatings

Key Engineering Materials ◽

10.4028/www.scientific.net/kem.522.167 ◽

2012 ◽

Vol 522 ◽

pp. 167-172 ◽

Cited By ~ 1

Author(s):

Zhao Hui Deng ◽

Qiao Ping Wu ◽

Lin Lin Wan ◽

Zhan Pan ◽

Gao Feng Zhang

Keyword(s):

Finite Element ◽

Temperature Field ◽

Finite Element Simulation ◽

Cutting Temperature ◽

Element Model ◽

Thermal Source ◽

Element Simulation ◽

Simulation And Experiment ◽

Machining Properties ◽

The Mathematical Model

To investigate the distribution of cutting temperature for surface cutting of nanastructured WC/12Co coating used the PDC cutter, according to machining properties of WC/12Co coating and working conditions, on the basis of the theory of thermal equilibrium of moving thermal source, the mathematical model of temperature field was established through reasonable hypothesis. Simulations were performed for the temperature distribution on the surface and inside the WC/12Co coating specimen using finite element method. And experiment of surface temperature of WC/12Co coating used the PDC cutter was carried out. The finite element simulation results were in good agreement with the experiment data, which verified the validation and capability of the finite element model.

Download Full-text