An Orthogonal Cutting Model Based on Finite Deformation Analysis: Part II — Constitutive Equations and Experimental Verification

1999 ◽  
Author(s):  
Y. Zheng ◽  
J. W. Sutherland
Keyword(s):  
Finite Deformation ◽  
Constitutive Equations ◽  
Orthogonal Cutting ◽  
Shear Angle ◽  
Deformation Analysis ◽  
Tool Steels ◽  
Model Based ◽  
Cutting Operation ◽  
Cutting Experiment ◽  
Cutting Model

Abstract In Part I of this paper, a model based on finite deformation analysis was developed to predict the forces in an orthogonal cutting operation. In the second part of the paper, the constitutive equations for O1 and L6 tool steels are developed using Hopkinson bar tests. A total of 90 statistically designed orthogonal cutting tests are conducted to investigate the cutting mechanics of O1 and L6 tool steels. Then the cutting model developed in Part I of this paper is applied to simulate all the 90 cutting tests using the measured material constitutive equations. All the measurable model outputs are calculated and compared with the corresponding cutting experiment results. The comparisons show that the cutting model based on finite deformation analysis can be successfully applied to predict the cutting forces, shear angle, and various relationships in machining (orthogonal cutting) tests.

Experimental Study on Effects of Feed per Tooth on Shear Angle and Friction Angle in Orthogonal Milling of Titanium Alloy

2014 ◽  
Vol 941-944 ◽  
pp. 1947-1951
Author(s):  
Wan Zhu Liu ◽  
Qiang Liu
Keyword(s):  
Titanium Alloy ◽  
Physical Phenomenon ◽  
Orthogonal Cutting ◽  
Friction Angle ◽  
Milling Process ◽  
Shear Angle ◽  
Experimental Results ◽  
Force Modeling ◽  
Increase With Increase ◽  
Cutting Model

Shear angle and friction angle are the two characteristic parameters in orthogonal cutting model. This paper investigated effects of feed per tooth on shear angle and friction angle in orthogonal milling of titanium alloy Ti6Al4V by experimental approach. Three different straight tooth milling tool with different rake angles are used in this research. Experimental results reveals that in orthogonal milling of Ti6Al4V alloy, shear angle will decrease with increase of feed per tooth and friction angle will increase with increase of feed per tooth. And then variation of shear angle and friction angle affect the values of force coefficients. The experimental results provide deep understand of basic physical phenomenon in milling process and sheds light on more accurate cutting force modeling.

Formation and Control of Two Side Direction Burr

2007 ◽  
Vol 24-25 ◽  
pp. 39-44 ◽  
Author(s):  
Gui Cheng Wang ◽  
Chun Gen Shen ◽  
Hong Jie Pei ◽  
Yun Ming Zhu ◽  
Qin Feng Li ◽  
...  
Keyword(s):  
Plane Stress ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Strain Theory ◽  
Burr Formation ◽  
Stress Strain ◽  
Cutting Operation ◽  
And Control ◽  
Cutting Model ◽  
Cutting Experiments

Based on the orthogonal cutting experiments, the two side direction burrs in metal cutting were studied. In this study, the cutting model of two side direction burr formation and translation is established with plane stress-strain theory. The main laws of formation and change of burr in size and type in orthogonal cutting are revealed, and it is confirmed by experiment results, which first realizes control of the forming and change of the two side direction burr in metal cutting operation.

An Orthogonal Cutting Model Based on Finite Deformation Analysis: Part I — Model Development

1999 ◽  
Author(s):  
Y. Zheng ◽  
J. W. Sutherland
Keyword(s):  
Constitutive Equation ◽  
Strain Rate ◽  
Finite Deformation ◽  
Deformation Theory ◽  
Orthogonal Cutting ◽  
Total Power ◽  
Eulerian Strain ◽  
Finite Deformation Theory ◽  
Material Constitutive Equation ◽  
Cutting Model

Abstract Based on the finite deformation theory of continuum mechanics, the velocity, Eulerian strain, Eulerian strain rate, and deformation rate distributions along a family of assumed streamlines are analytically obtained for an orthogonal cutting operation. An iterative incremental method is used to predict the temperature on the shear plane. The total power in orthogonal cutting may be expressed in terms of three parameters, which are predicted by minimization of the total power. This model allows a general form for the material constitutive equation, which, in general, is a function of strain, strain rate, and temperature. The rotation effect of streamlines on the strain and strain rate calculations is automatically considered using the finite deformation theory of continuum mechanics. In Part I of this paper, the theoretical underpinning for the orthogonal cutting model is established. The verification of the model, including determination of the material constitutive equation using the Hopkinson bar technique, is presented in Part II of this paper.

On Methodologies inside Two Different Commercial Codes to Simulate the Cutting Operation

2011 ◽  
Vol 223 ◽  
pp. 162-171
Author(s):  
Yan Cheng Zhang ◽  
Domenico Umbrello ◽  
Tarek Mabrouki ◽  
Stefania Rizzuti ◽  
Daniel Nelias ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Titanium Alloy ◽  
Surface Integrity ◽  
Chip Formation ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Cutting Parameters ◽  
Cutting Operation ◽  
Cutting Processes ◽  
Cutting Model

Nowadays, numerical simulation of cutting processes receives considerable interest among the scientific and industrial communities. For that, various numerical codes are used. Nevertheless, there is no uniform standard for the comparison of simulation model with these different software. So, it is often not easy to state if a given code is more pertinent than another. In this framework, the present work deals with various methodologies to simulate orthogonal cutting operation inside two commercial codes Abaqus and Deform. The aim of the present paper is to build a common benchmark model between the two pre-cited codes which can initiate other numerical cutting model comparisons. The study is focused on the typical aeronautical material - Ti-6Al-4V - Titanium alloy. In order to carry out a comparative study between the two codes, some similar conditions concerning geometrical models and cutting parameters were respected. A multi-physic comprehension related to chip formation, cutting forces and temperature evolutions, and surface integrity is presented. Moreover, the numerical results are compared with experimental ones.

scholarly journals Model of Ploughing Cortical Bone with Single-Point Diamond Tool

Materials ◽  
2021 ◽  
Vol 14 (21) ◽  
pp. 6530
Author(s):  
Jing Ni ◽  
Yang Wang ◽  
Zhen Meng ◽  
Jun Cai ◽  
Kai Feng ◽  
...  
Keyword(s):  
Cortical Bone ◽  
Bone Repair ◽  
Bone Cells ◽  
Single Point ◽  
Orthogonal Cutting ◽  
Tangential Force ◽  
Cutting Experiment ◽  
Proportional Relationship ◽  
Surface Microstructures ◽  
Cutting Model

Generating topological microstructures on the surface of cortical bone to establish a suitable microenvironment can guide bone cells to achieve bone repair. Single-point diamond tools (SPDTs) have advantages in efficiency and flexibility to fabricate surface microstructures. However, the cutting force during ploughing cannot be predicted and controlled due to the special properties of cortical bone. In this paper, a novel cutting model for ploughing cortical bone using an SPDT was established, and we comprehensively considered the shear stress anisotropy of the bone material and the proportional relationship between the normal force and the tangential force. Then, the orthogonal cutting experiment was used to verify the model. The results show that the error of calculated value and the experimental data is less than 5%. The proposed model can be used to assist the fabrication of microstructures on cortical bone surface using an SPDT.

Application of Finite Deformation Theory to the Development of an Orthogonal Cutting Model—Part II: Experimental Investigation and Model Validation

2005 ◽  
Vol 128 (3) ◽  
pp. 767-774 ◽  
Author(s):  
Yuliu Zheng ◽  
Xuefei Hu ◽  
John W. Sutherland
Keyword(s):  
Continuum Mechanics ◽  
Finite Deformation ◽  
Deformation Theory ◽  
Split Hopkinson Pressure Bar ◽  
Orthogonal Cutting ◽  
Hopkinson Pressure Bar ◽  
Mechanics Model ◽  
Finite Deformation Theory ◽  
Cutting Model ◽  
The Continuum

In Part 1 of this paper, a continuum mechanics model of the orthogonal cutting process was developed based on finite deformation theory. In this part of the paper, constitutive equations for O1 and L6 tool steels are developed using the results from split Hopkinson pressure bar tests. Statistically designed orthogonal cutting experiments are conducted to secure process results across a range of cutting conditions. The continuum mechanics model established in Part 1 of this paper is used to simulate all the cutting tests. All the model outputs are calculated and compared with the corresponding cutting experiment results. Good agreement is observed between the model predictions and the experimental results. The continuum mechanics model is successfully used to predict the cutting force, shear angle, and temperature.

Application of Finite Deformation Theory to the Development of an Orthogonal Cutting Model—Part I: Model Development

2005 ◽  
Vol 128 (3) ◽  
pp. 760-766
Author(s):  
Yuliu Zheng ◽  
Xuefei Hu ◽  
John W. Sutherland
Keyword(s):  
Constitutive Equation ◽  
Strain Rate ◽  
Continuum Mechanics ◽  
Finite Deformation ◽  
Deformation Theory ◽  
Orthogonal Cutting ◽  
Total Power ◽  
Eulerian Strain ◽  
Finite Deformation Theory ◽  
Cutting Model

An orthogonal cutting model is developed using the finite deformation theory of continuum mechanics. A family of flowlines is proposed to describe the chip flow during orthogonal cutting, and the shape of the flowlines is described in terms of three parameters, one of which is the shear angle. The velocity, Eulerian strain, and Eulerian strain rate distribution along the assumed flowlines are obtained analytically for the orthogonal cutting operation based on this model. The temperature distribution along the flowline is predicted via a finite difference method. Values for the three flowline parameters are selected that minimize the total power associated with primary shear zone deformation and chip-tool interaction using the Davidon-Fletcher-Powell optimization scheme. The model utilizes a general constitutive equation for material behavior, which is a function of strain, strain rate, and temperature. In Part I of this two-part paper, the continuum mechanics-based model for the orthogonal cutting process is established. Experimental assessment and adequacy checking of the model, including determination of the material constitutive equation using a split Hopkinson pressure bar technique, is presented in Part II of the paper.

Sign in / Sign up

Export Citation Format

Share Document