Predictive Analytical and Thermal Modeling of Orthogonal Cutting Process—Part II: Effect of Tool Flank Wear on Tool Forces, Stresses, and Temperature Distributions

2005 ◽  
Vol 128 (2) ◽  
pp. 445-453 ◽  
Author(s):  
Yiğit Karpat ◽  
Tuğrul Özel
Keyword(s):  
Flank Wear ◽  
Thermal Modeling ◽  
Orthogonal Cutting ◽  
Force Model ◽  
Stress Distributions ◽  
Tool Flank Wear ◽  
Temperature Distributions ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

In this paper, predictive modeling of cutting and ploughing forces, stress distributions on tool faces, and temperature distributions in the presence of tool flank wear are presented. The analytical and thermal modeling of orthogonal cutting that is introduced in Part I of the paper is extended for worn tool case in order to study the effect of flank wear on the predictions. Work material constitutive model based formulations of tool forces and stress distributions at tool rake and worn flank faces are utilized in calculating nonuniform heat intensities and heat partition ratios induced by shearing, tool-chip interface friction, and tool flank face-workpiece interface contacts. In order to model forces and stress distributions under the flank wear zone, a force model from Waldorf (1996) (“Shearing Ploughing, and Wear in Orthogonal Machining,” Ph.D. thesis, University of Illinois at Urbana-Champaign, IL) is adapted. Model is tested and validated for temperature and force predictions in machining of AISI 1045 steel and AL 6061-T6 aluminum.

An Analytical-Thermal Modeling Approach for Predicting Forces, Stresses and Temperatures in Machining With Worn Tools

2005 ◽  
Author(s):  
Yigit Karpat ◽  
Tugrul O¨zel
Keyword(s):  
Flank Wear ◽  
Thermal Modeling ◽  
Orthogonal Cutting ◽  
Force Model ◽  
Stress Distributions ◽  
Heat Partition ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Flank Face ◽  
1045 Steel

In this paper, predictive modeling of cutting and ploughing forces, stress distributions on tool faces and temperature distributions in the presence of tool flank wear are presented. The analytical and thermal modeling of orthogonal cutting that is introduced in Karpat, Zeren and O¨zel [3] extended for worn tool case in order to study the effect of flank wear on the predictions. Work material constitutive model based formulations of tool forces and stress distributions at tool rake and worn flank faces are utilized in calculating non-uniform heat intensities and heat partition ratios induced by shearing, tool-chip interface friction and tool flank face-workpiece interface contacts. In order to model forces and stress distributions under the flank wear zone, a force model from Waldorf [4] is adapted. Model is tested and validated for temperature and force predictions in machining of AISI 1045 steel and AL 6061-T6 aluminum.

New Thermal Issues on the Modelling of Tool-Workpiece Interaction: Application to Dry Cutting of AISI 1045 Steel

2011 ◽  
Vol 223 ◽  
pp. 286-295 ◽  
Author(s):  
Cédric Courbon ◽  
Tarek Mabrouki ◽  
Joël Rech ◽  
Denis Mazuyer ◽  
Enrico D'Eramo
Keyword(s):  
Heat Flux ◽  
Hot Spot ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Contact Length ◽  
Dry Cutting ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Carbide

The present work proposes to enhance the thermal interface denition in Finite Element (FE) simulations of machining. A user subroutine has been developed in Abaqus/Explicit © to implement a new experimentally-based heat partition model extracted from tribological tests. A 2D Arbitrary-Lagragian-Eulerian (ALE) approach is employed to simulate dry orthogonal cutting of AISI 1045 steel with coated carbide inserts. Simulation results are compared to experimental ones over a whole range of cutting speeds and feed rates in terms of average cutting forces, chip thickness, tool chip contact length and heat flux. This study emphasizes that heat transfer and temperature distribution in the cutting tool are drastically in uenced by the thermal formulation used at the interface. Consistency of the numerical results such as heat flux transmitted to the tool, peak temperature as well as hot spot location can be denitively improved.

A Metallo-Thermomechanically Coupled Analysis of Orthogonal Cutting of AISI 1045 Steel

2012 ◽  
Vol 134 (5) ◽  
Author(s):  
Hongtao Ding ◽  
Yung C. Shin
Keyword(s):  
Experimental Data ◽  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Machining Process ◽  
Coupled Analysis ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Materials often behave in a complicated manner involving deeply coupled effects among stress/stain, temperature, and microstructure during a machining process. This paper is concerned with prediction of the phase change effect on orthogonal cutting of American Iron and Steel Institute (AISI) 1045 steel based on a true metallo-thermomechanical coupled analysis. A metallo-thermomechanical coupled material model is developed and a finite element model (FEM) is used to solve the evolution of phase constituents, cutting temperature, chip morphology, and cutting force simultaneously using abaqus. The model validity is assessed using the experimental data for orthogonal cutting of AISI 1045 steel under various conditions, with cutting speeds ranging from 198 to 879 m/min, feeds from 0.1 to 0.3 mm, and tool rake angles from −7 deg to 5 deg. A good agreement is achieved in chip formation, cutting force, and cutting temperature between the model predictions and the experimental data.

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.

New Experiments on the Temperature Distribution in Drilling

1984 ◽  
Vol 106 (3) ◽  
pp. 242-247 ◽  
Author(s):  
A. Thangaraj ◽  
P. K. Wright ◽  
M. Nissle
Keyword(s):  
Temperature Distribution ◽  
High Speed ◽  
Metal Flow ◽  
High Speed Steel ◽  
Twist Drill ◽  
Temperature Distributions ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Twist Drills

Using metallographic and microhardness techniques, temperature distributions have been determined in twist drills. The methods rely on the fact that certain high speed steel materials exhibit microstructural changes when subjected to temperatures greater than 600°C. Quick-stop specimens have also been obtained to study the metal flow patterns over the drill flutes. These results have been used to comment on the different wear mechanisms that affect the performance of a twist drill. Preliminary results show that bulk plastic flow occurs near the margin of the drill where the temperatures are in the vicinity of 900°C when machining AISI 1045 steel at 40 m/min.

scholarly journals Selection of Machining Parameters Using a Correlative Study of Cutting Tool Wear in High-Speed Turning of AISI 1045 Steel

2018 ◽  
Vol 2 (4) ◽  
pp. 66 ◽  
Author(s):  
Luis Hernández González ◽  
Yassmin Seid Ahmed ◽  
Roberto Pérez Rodríguez ◽  
Patricia Zambrano Robledo ◽  
Martha Guerrero Mata
Keyword(s):  
High Speed ◽  
Manufacturing Industry ◽  
Cutting Tool ◽  
Flank Wear ◽  
Machining Parameters ◽  
High Speed Turning ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Carbide

The manufacturing industry aims to produce many high quality products efficiently at low cost, thereby motivating companies to use advanced manufacturing technologies. The use of high-speed machining is increasingly widespread; however, it lacks a deep-rooted knowledge base needed to facilitate implementation. In this paper, response surface methodology (RSM) has been applied to determine the optimum cutting conditions leading to minimum flank wear in high-speed dry turning on AISI 1045 steel. The mathematical models in terms of machining parameters were developed for flank wear prediction using RSM on the basis of experimental results. The high speed turning experiments were carried out with two coated carbide and a cermet inserts using AISI 1045 steel as work material at different cutting speeds and machining times. The models selected for optimization were validated through the Pareto principle. Results showed the GC4215 insert to be the most optimal option, because it did not reach the cutting tool life limit and could be used for the whole range of cutting parameters selected. To quantitatively evaluate the usefulness of the cutting tools, it was proposed the coefficient of use of the tools from the results of the contour graphs. The GC4215 insert showed 100% effectiveness, followed by the GC4225 with 98.4%, and finally, the CT5015 insert with 83%.

Prelimenary Study on Thermomechanical Modelling of Cutting Process

2011 ◽  
Vol 383-390 ◽  
pp. 6741-6746
Author(s):  
Wan Masrurah Bt Hairudin ◽  
Mokhtar B. Awang
Keyword(s):  
Maximum Stress ◽  
Orthogonal Cutting ◽  
Cutting Process ◽  
Maximum Temperature ◽  
Arbitrary Lagrangian Eulerian ◽  
Element Analysis ◽  
Ale Formulation ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

In this paper, thermo mechanical modelling of cutting process has been developed using a commercially available finite element analysis software, ABAQUS. A 2-D orthogonal cutting has been modelled using Arbitrary Lagrangian-Eulerian (ALE) formulation. The Johnson-Cook plasticity model has been assumed to describe the material behaviour during the process. This study is aimed at temperature and stresses distributions during machining of AISI 1045 steel with different rake angles; α=0° and α= -10°. The results showed that the maximum stress for 0° and -10° are 963MPa and 967MPa while the maximum temperature results shown that 771°C and 347°C.

Predictive Analytical and Thermal Modeling of Orthogonal Cutting Process—Part I: Predictions of Tool Forces, Stresses, and Temperature Distributions

2005 ◽  
Vol 128 (2) ◽  
pp. 435-444 ◽  
Author(s):  
Yiğit Karpat ◽  
Tuğrul Özel
Keyword(s):  
Shear Zone ◽  
Thermal Modeling ◽  
Orthogonal Cutting ◽  
Cutting Process ◽  
Field Analysis ◽  
Normal Stress Distribution ◽  
Modeling Approach ◽  
Temperature Distributions ◽  
Secondary Shear Zone ◽  
1045 Steel

In this paper, a predictive thermal and analytical modeling approach for orthogonal cutting process is introduced to conveniently calculate forces, stress, and temperature distributions. The modeling approach is based on the work material constitutive model, which depends on strain, strain rate, and temperature. In thermal modeling, oblique moving band heat source theory is utilized and analytically combined with modified Oxley’s parallel shear zone theory. Normal stress distribution on the tool rake face is modeled as nonuniform with a power-law relationship. Hence, nonuniform heat intensity at the tool-chip interface is obtained from the predicted stress distributions utilizing slip line field analysis of the modified secondary shear zone. Heat sources from shearing in the primary zone and friction at the tool-chip interface are combined, heat partition ratios are determined for temperature equilibrium to obtain temperature distributions depending on cutting conditions. Model validation is performed by comparing some experimental results with the predictions for machining of AISI 1045 steel, AL 6082-T6, and AL 6061-T6 aluminum. Close agreements with the experiments are observed. A set of detailed, analytically computed stress and temperature distributions is presented.

scholarly journals A Numerical-Experimental Study on Orthogonal Cutting of AISI 1045 Steel and Ti6Al4V Alloy: SPH and FEM Modeling with Newly Identified Friction Coefficients

Metals ◽  
2021 ◽  
Vol 11 (11) ◽  
pp. 1683
Author(s):  
Mohamadreza Afrasiabi ◽  
Jannis Saelzer ◽  
Sebastian Berger ◽  
Ivan Iovkov ◽  
Hagen Klippel ◽  
...  
Keyword(s):  
Metal Cutting ◽  
Experimental Validation ◽  
Orthogonal Cutting ◽  
Thermal Loads ◽  
Rake Face ◽  
Friction Coefficients ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Face Temperature

Numerical simulation of metal cutting with rigorous experimental validation is a profitable approach that facilitates process optimization and better productivity. In this work, we apply the Smoothed Particle Hydrodynamics (SPH) and Finite Element Method (FEM) to simulate the chip formation process within a thermo-mechanically coupled framework. A series of cutting experiments on two widely-used workpiece materials, i.e., AISI 1045 steel and Ti6Al4V titanium alloy, is conducted for validation purposes. Furthermore, we present a novel technique to measure the rake face temperature without manipulating the chip flow within the experimental framework, which offers a new quality of the experimental validation of thermal loads in orthogonal metal cutting. All material parameters and friction coefficients are identified in-situ, proposing new values for temperature-dependent and velocity-dependent friction coefficients of AISI 1045 and Ti6Al4V under the cutting conditions. Simulation results show that the choice of friction coefficient has a higher impact on SPH forces than FEM. Average errors of force prediction for SPH and FEM were in the range of 33% and 23%, respectively. Except for the rake face temperature of Ti6Al4V, both SPH and FEM provide accurate predictions of thermal loads with 5–20% error.

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