Evaluation of Ductile Fracture Models in Finite Element Simulation of Metal Cutting Processes

2013 ◽  
Vol 136 (1) ◽  
Author(s):  
Jian Liu ◽  
Yuanli Bai ◽  
Chengying Xu
Keyword(s):  
Finite Element ◽  
Ductile Fracture ◽  
Damage Evolution ◽  
Metal Cutting ◽  
Fracture Criterion ◽  
Orthogonal Cutting ◽  
Systematic Evaluation ◽  
Fe Model ◽  
Fracture Models ◽  
Cutting Processes

In this paper, a systematic evaluation of six ductile fracture models is conducted to identify the most suitable fracture criterion for metal cutting processes. Six fracture models are evaluated in this study, including constant fracture strain, Johnson-Cook, Johnson-Cook coupling criterion, Wilkins, modified Cockcroft-Latham, and Bao-Wierzbicki fracture criterion. By means of abaqus built-in commands and a user material subroutine (VUMAT), these fracture models are implemented into a finite element (FE) model of orthogonal cutting processes in abaqus/Explicit platform. The local parameters (stress, strain, fracture factor, and velocity fields) and global variables (chip morphology, cutting forces, temperature, shear angle, and machined surface integrity) are evaluated. The numerical simulation results are examined by comparing to experimental results of 2024-T3 aluminum alloy published in the open literature. Based on the results, it is found that damage evolution should be considered in cutting process FE simulation. Moreover, the B-W fracture model with consideration of rate dependency, temperature effect and damage evolution gives the best prediction of chip removal behavior of ductile metals.

3D Finite Element Simulation on the Orthogonal Cutting Processes with Different Commercial Codes

2011 ◽  
Vol 188 ◽  
pp. 555-560
Author(s):  
Zhao Yu Mou ◽  
Peng Fei Gao ◽  
Wei Fang Wang ◽  
Dong Hui Wen
Keyword(s):  
Finite Element ◽  
Metal Cutting ◽  
Orthogonal Experiment ◽  
Orthogonal Cutting ◽  
Friction Model ◽  
Element Simulation ◽  
Cutting Experiment ◽  
Type Boundary ◽  
Cutting Processes ◽  
Type Boundary Condition

The purpose of this paper is to compare different simulation model of orthogonal cutting process using three different FEM commercial codes as well as with the results of orthogonal experiment. For one thing, element type, boundary condition and friction model between the chip and tool commercial have been compared when the numerical model established in implicit finite element code, Deform3D and the explicit code ANSYS/LS-DYNA and Thirdwave AdvantEdge. For another, main and thrust cutting forces, shear angles, chip thicknesses and contact lengths by three codes are compared with the orthogonal metal cutting experiment by Movahhedy and Altintas.

Finite Element Simulation of the Orthogonal Metal Cutting Process

2004 ◽  
Vol 471-472 ◽  
pp. 582-586 ◽  
Author(s):  
Shi Jin Chen ◽  
Q.L. Pang ◽  
K. Cheng
Keyword(s):  
Finite Element ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Cutting Process ◽  
Machined Surface ◽  
Cutting Test ◽  
Orthogonal Metal Cutting ◽  
Discontinuous Cutting ◽  
Cutting Processes

In this paper, a finite element model of a two-dimensional orthogonal metal cutting process is used to simulate the chip formation, cutting forces, stress, strain and temperature distributions. Two deformable parts are involved in this model: the workpiece and the cutting tool. To make the results of the simulation agree the orthogonal cutting test better, the separation surface between the chip and the machined surface is not predefined in this simulation. The chip-separation criterion is based on the Johnson and Cook law. This work will help as a reference to tackle more complex cutting processes such as oblique and discontinuous cutting.

scholarly journals Adaptive Particle Finite Element Method (A‐PFEM) in Metal Cutting Processes

PAMM ◽  
2021 ◽  
Vol 20 (1) ◽  
Author(s):  
Xialong Ye ◽  
Juan Manuel Rodríguez Prieto ◽  
Ralf Müller
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Metal Cutting ◽  
Particle Finite Element Method ◽  
Cutting Processes ◽  
Element Method

scholarly journals Finite Element Analysis of Bore-expanding Processes with Ductile Fracture Criterion

1998 ◽  
Vol 84 (3) ◽  
pp. 182-187 ◽  
Author(s):  
Hirohiko TAKUDA ◽  
Ken-ichiro MORI ◽  
Masashi KANESHIRO ◽  
Natsuo HATTA
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Ductile Fracture ◽  
Fracture Criterion ◽  
Ductile Fracture Criterion ◽  
Element Analysis

scholarly journals Investigation of the Cutting Uid'S Ow and its Thermomechanical Effect on the Cutting Zone Based on Uid-Structure Interaction (FSI) Simulation

2021 ◽  
Author(s):  
Hui Liu ◽  
Markus Meurer ◽  
Daniel Schraknepper ◽  
Thomas Bergs
Keyword(s):  
Metal Cutting ◽  
Negative Impact ◽  
Orthogonal Cutting ◽  
Fluid Simulation ◽  
Cutting Fluid ◽  
Cutting Fluids ◽  
Thermomechanical Effect ◽  
Dimensional Simulation ◽  
On Chip ◽  
Cutting Processes

Abstract Cutting fluids are an important part of today's metal cutting processes, especially when machining aerospace alloys. They offer the possibility to extend tool life and improve cutting performance. However, the equipment and handling of cutting fluids also raises manufacturing costs. To reduce the negative impact of the high cost of cutting fluids, cooling systems and strategies are constantly being optimized. In most existing works, the influences of different cooling strategies on the relevant process parameters, such as tool wear, cutting forces, chip breakage, etc., are empirically investigated. Due to the limitations of experimental methods, analysis and modeling of the working mechanism has so far only been carried out at a relatively abstract level. For a better understanding of the mechanism of cutting fluids, a thermal coupled two-dimensional simulation approach for the orthogonal cutting process was developed in this work. This approach is based on the Coupled Eulerian Lagrangian (CEL) method and provides a detailed investigation of the cutting fluid’s impact on chip formation and tool temperature. For model validation, cutting tests were conducted on a broaching machine. The simulation resolved the fluid behavior in the cutting area and showed the distribution of convective cooling on the tool surface. This work demonstrates the potential of CEL based cutting fluid simulation, but also pointed out the shortcomings of this method.

FEM Simulation of the Residual Stress in the Machined Surface Layer for High-Speed Machining

2006 ◽  
Vol 315-316 ◽  
pp. 140-144 ◽  
Author(s):  
Su Yu Wang ◽  
Xing Ai ◽  
Jun Zhao ◽  
Z.J. Lv
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Surface Layer ◽  
Residual Stresses ◽  
High Speed ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
High Speed Machining ◽  
Machined Surface ◽  
Cutting Model

An orthogonal cutting model was presented to simulate high-speed machining (HSM) process based on metal cutting theory and finite element method (FEM). The residual stresses in the machined surface layer were obtained with various cutting speeds using finite element simulation. The variations of residual stresses in the cutting direction and beneath the workpiece surface were studied. It is shown that the thermal load produced at higher cutting speed is the primary factor affecting the residual stress in the machined surface layer.

Influence of the Process Variables on the Temperature Distribution in AISI 1045 Turning

2012 ◽  
Vol 557-559 ◽  
pp. 1364-1368
Author(s):  
Yong Feng ◽  
Mu Lan Wang ◽  
Bao Sheng Wang ◽  
Jun Ming Hou
Keyword(s):  
Temperature Distribution ◽  
High Speed ◽  
Metal Cutting ◽  
Constitutive Relations ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Fe Model ◽  
Process Variables ◽  
Machined Surface ◽  
Aisi 1045

High-speed metal cutting processes can cause extremely rapid heating of the work material. Temperature on the machined surface is critical for surface integrity and the performance of a precision component. However, the temperature of a machined surface is challenging for in-situ measurement.So, the finite element(FE) method used to analyze the unique nonlinear problems during cutting process. In terms of heat-force coupled problem, the thermo-plastic FE model was proposed to predict the cutting temperature distribution using separated iterative method. Several key techniques such as material constitutive relations, tool-chip interface friction and separation and damage fracture criterion were modeled. Based on the updated Lagrange and arbitrary Lagrangian-Eulerian (ALE) method, the temperature field in high speed orthogonal cutting of carbon steel AISI-1045 were simulated. The simulated results showed good agreement with the experimental results, which validated the precision of the process simulation method. Meanwhile, the influence of the process variables such as cutting speed, cutting depth, etc. on the temperature distribution was investigated.

Temperature Field Numerical Analysis of Machining Process Based on the Finite Element Analysis

2014 ◽  
Vol 621 ◽  
pp. 611-616 ◽  
Author(s):  
Yan Juan Hu ◽  
Yao Wang ◽  
Zhan Li Wang
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Element Model ◽  
Machining Process ◽  
Element Analysis ◽  
Mechanical Coupling

In order to study the temperature field distribution in the process of machining, the finite element theory was used to establish the orthogonal cutting finite element model, and the key technologies were discussed simultaneously. By using ABAQUS software for cutting AISI1045 steel temperature field of numerical simulation, the conclusion about changing rule of cutting temperature field can be gotten. The results show that this method can efficiently simulate the distribution of temperature field of the workpiece, cutter and scraps, which is effected by thermo-mechanical coupling in metal work process. It provides the theory evidence for the intensive study of metal-cutting principle, optimizing cutting parameters and improving processing technic and so on.

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