A Finite Element Model of Orthogonal Metal Cutting

1985 ◽  
Vol 107 (4) ◽  
pp. 349-354 ◽  
Author(s):  
J. S. Strenkowski ◽  
J. T. Carroll
Keyword(s):  
Finite Element ◽  
Plastic Strain ◽  
Residual Stresses ◽  
Finite Element Model ◽  
Metal Cutting ◽  
Element Model ◽  
Effective Plastic Strain ◽  
Orthogonal Metal Cutting ◽  
Chip Separation ◽  
Chip Geometry

A finite element model of orthogonal metal cutting is described. The paper introduces a new chip separation criterion based on the effective plastic strain in the workpiece. Several cutting parameters that are often neglected in simplified metal-cutting models are included, such as elastic-plastic material properties of both the workpiece and tool, friction along the tool rake face, and geometry of the cutting edge and workpiece. The model predicts chip geometry, residual stresses in the workpiece, and tool stresses and forces, without any reliance on empirical metal cutting data. The paper demonstrates that use of a chip separation criterion based on effective plastic strain is essential in predicting chip geometry and residual stresses with the finite element method.

The Establishment of Orthogonal Cutting Finite Element Model and its Key Technologies

2009 ◽  
Vol 416 ◽  
pp. 568-571
Author(s):  
You Yi Zheng ◽  
Ai Hua Gao
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Key Technology ◽  
Element Simulation ◽  
Key Technologies ◽  
Orthogonal Metal Cutting ◽  
The Finite Element Model

Based on several assumptions, this paper established the finite element model of the heat coupling of the orthogonal metal cutting, and analyzes the key technology that involved in the Orthogonal cutting finite element simulation.

Finite Element Prediction of Chip Geometry and Tool/Workpiece Temperature Distributions in Orthogonal Metal Cutting

1990 ◽  
Vol 112 (4) ◽  
pp. 313-318 ◽  
Author(s):  
J. S. Strenkowski ◽  
Kyoung-Jin Moon
Keyword(s):  
Finite Element ◽  
Metal Cutting ◽  
Shear Plane ◽  
Element Model ◽  
Contact Length ◽  
Interface Temperature ◽  
Orthogonal Metal Cutting ◽  
Stress And Strain Rate ◽  
Chip Geometry ◽  
Cutting Experiments

An Eulerian finite element model is presented that simulates orthogonal metal cutting. The model predicts chip geometry and temperature distribution in the workpiece, chip, and tool without the need for empirical cutting data. With the capability to predict chip geometry, the tool-chip contact length can also be found. Characteristics of the flow field in the vicinity of the tool can also be determined, such as the material velocity, and the stress and strain-rate distributions. It was found that the shear stress occurs over a finite region in front of the tool, rather than a single shear plane. Cutting experiments were performed for aluminum alloy 6061-T6 to validate the model. Good correlation with the model was found based on tool forces and average tool-chip interface temperature measurements.

Effect of Rounded Cutting Edge Radius on Residual Stress within Machined Sublayer

2006 ◽  
Vol 532-533 ◽  
pp. 536-539
Author(s):  
Wen Jun Deng ◽  
Yong Tang ◽  
Wei Xia ◽  
Zhen Ping Wan
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Residual Stresses ◽  
Finite Element Model ◽  
Metal Cutting ◽  
Element Model ◽  
Cutting Edge ◽  
Workpiece Material ◽  
Cutting Edge Radius ◽  
Edge Radius

A coupled thermal-mechanical model of plane-strain orthogonal metal cutting with continuous chip formation is developed to investigate the residual stresses in the finished workpiece. Deformation of the workpiece material is treated as elastic-viscoplastic with isotropic strain hardening, and the numerical solution accounts for coupling between plastic deformation and the temperature field, including treatment of temperature-dependent material properties. Automatic continuous remeshing and adaptive meshing technique are employed to achieve chip separation at the tool tip region and a satisfactory solution. The finite element model is well validated by comparing values of the predicted cutting forces and residual stresses with experimental results. Based on the established finite element model, the effect of rounded cutting edge radius on residual stress distribution is analyzed. The results show that altered cutting edge radius clearly produced significant changes in residual stresses. The maximum tensile residual stress and its penetration depth decrease as the cutting edge radius increases.

scholarly journals Investigation of the Thickness Differential on the Formability of Aluminum Tailor Welded Blanks

Metals ◽  
2021 ◽  
Vol 11 (6) ◽  
pp. 875
Author(s):  
Jie Wu ◽  
Yuri Hovanski ◽  
Michael Miles
Keyword(s):  
Experimental Data ◽  
Finite Element ◽  
Numerical Model ◽  
Plastic Strain ◽  
Finite Element Model ◽  
Equivalent Plastic Strain ◽  
Element Model ◽  
Dome Height ◽  
Tailor Welded Blanks ◽  
Simulation Results

A finite element model is proposed to investigate the effect of thickness differential on Limiting Dome Height (LDH) testing of aluminum tailor-welded blanks. The numerical model is validated via comparison of the equivalent plastic strain and displacement distribution between the simulation results and the experimental data. The normalized equivalent plastic strain and normalized LDH values are proposed as a means of quantifying the influence of thickness differential for a variety of different ratios. Increasing thickness differential was found to decrease the normalized equivalent plastic strain and normalized LDH values, this providing an evaluation of blank formability.

scholarly journals Numerical investigation of plastic flow and residual stresses generated in hydroformed tubes

2021 ◽  
pp. 146442072198974
Author(s):  
A Ktari ◽  
A Abdelkefi ◽  
N Guermazi ◽  
P Malecot ◽  
N Boudeau
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Finite Element Model ◽  
Plastic Flow ◽  
Tube Hydroforming ◽  
Three Dimensional ◽  
Element Model ◽  
Tube Cross Section ◽  
Straight Wall ◽  
Hydroforming Process

During tube hydroforming process, the friction conditions between the tube and the die have a great importance on the material plastic flow and the distribution of residual stresses of the final component. Indeed, a three-dimensional finite element model of a tube hydroforming process in the case of square section die has been performed, using dynamic and static approaches, to study the effect of the friction conditions on both plastic flow and residual stresses induced by the process. First, a comparative study between numerical and experimental results has been carried out to validate the finite element model. After that, various coefficients of friction were considered to study their effect on the thinning phenomenon and the residual stresses distribution. Different points have been retained from this study. The thinning is located in the transition zone cited between the straight wall and the corner zones of hydroformed tube due to the die–tube contact conditions changes during the process. In addition, it is clear that both die–tube friction conditions and the tube bending effects, which occurs respectively in the tube straight wall and corner zones, are the principal causes of the obtained residual stresses distribution along the tube cross-section.

Tube-to-Tubesheet Joints: Maximum Tensile Stress and Contact Pressure Due to Thermal Loading and Temperature Cycling

2002 ◽  
Author(s):  
Mahdi A. Allam ◽  
Andre Bazergui ◽  
Luc Marchand ◽  
Michel Derenne
Keyword(s):  
Finite Element ◽  
Residual Stresses ◽  
Finite Element Model ◽  
Contact Pressure ◽  
Thermal Loading ◽  
Element Model ◽  
Maximum Tensile Stress ◽  
Temperature Cycling ◽  
Operating Conditions ◽  
Service Reliability

Service reliability and durability of tubular heat exchangers and steam generators are much dependent on the proper response of the tube-to-tubesheet joints to the operating conditions. In this paper a 2-D axisymmetric finite element model is proposed and compared to a 3-D finite element solution for the purpose of predicting the temperature effect on the residual contact pressure and maximum tensile residual stresses of such joints. A parametric study using the finite element results shows that, although thermal loading and temperature cycling have a negligible effect on the maximum tensile residual stresses, the room-temperature initial residual contact pressure may be completely relieved following the initiation of plastic deformation in either the tube or the tubesheet during thermal loading. A comparison between the results of the proposed finite element model and those obtained from the literature shows good agreement. A simplified analytical approach, which may be used for the design of tube-to-tubesheet joints, is also proposed to predict the joint behavior at the operating conditions.

Bodner-Partom Constitutive Model and Nonlinear Finite Element Analysis

1990 ◽  
Vol 112 (3) ◽  
pp. 287-291 ◽  
Author(s):  
F. A. Kolkailah ◽  
A. J. McPhate
Keyword(s):  
Experimental Data ◽  
Finite Element ◽  
Plastic Strain ◽  
Constitutive Model ◽  
Finite Element Model ◽  
Numerical Technique ◽  
Element Model ◽  
Material Behavior ◽  
Model Parameters ◽  
Elastic Plastic

In this paper, results from an elastic-plastic finite-element model incorporating the Bodner-Partom model of nonlinear time-dependent material behavior are presented. The parameters in the constitutive model are computed from a leastsquare fit to experimental data obtained from uniaxial stress-strain and creep tests at 650°C. The finite element model of a double-notched specimen is employed to determine the value of the elastic-plastic strain and is compared to experimental data. The constitutive model parameters evaluated in this paper are found to be in good agreement with those obtained by the other investigators. However, the parameters determined by the numerical technique tend to give response that agree with the data better than do graphically determined parameters previously used. The calculated elastic-plastic strain from the model agreed well with the experimental strain.

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