Possibilities and Problems in Finite Element Simulations of High Speed Cutting Mechanics

2004 ◽  
Author(s):  
Arno Behrens ◽  
Karsten Kalisch ◽  
Jens P. Wulfsberg
Keyword(s):  
Finite Element ◽  
Chip Formation ◽  
High Speed ◽  
Temperature Fields ◽  
Research Association ◽  
Theoretical Understanding ◽  
High Speed Cutting ◽  
Simulation Techniques ◽  
Element Simulation ◽  
Modern Manufacturing

High speed cutting (HSC) has received growing attention in recent years due to its widespread applications in modern manufacturing. However, the theoretical understanding of the HSC process is considerably underdeveloped in comparison to the rapid progress of its practical application. To improve the state of knowledge of this topic, the German Research Association (DFG) has funded some research projects. One of them is the improvement of finite element simulation techniques of the HSC process. It covers the chip formation description, development of material laws for the description of HSC-conditions, the prediction of lamellar chips, the calculation of residual stresses, resulting temperature fields in the cutting tool and first descriptions of spatial chip formation. The paper will give an overview of the current progress in this project.

Finite Element Simulation on High Speed Cutting of Hardened 45 Steel Based on ABAQUS

2013 ◽  
Vol 579-580 ◽  
pp. 202-207
Author(s):  
Guo He Li ◽  
Hou Jun Qi ◽  
Bing Yan
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Finite Element Simulation ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Cutting Process ◽  
High Speed Cutting ◽  
Geometry Model ◽  
Element Simulation

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.

Finite Element Investigation of the Influence of Thermophysical Parameters on Segmented Chip Formation during High Speed Cutting

2011 ◽  
Vol 130-134 ◽  
pp. 2817-2821
Author(s):  
You Xi Lin ◽  
Cong Ming Yan
Keyword(s):  
Thermal Conductivity ◽  
Finite Element ◽  
Specific Heat ◽  
Chip Formation ◽  
High Speed ◽  
Element Model ◽  
Serrated Chip ◽  
High Speed Cutting ◽  
Thermophysical Parameters ◽  
Serrated Chip Formation

A 2D fully thermal mechanical coupled finite element model is applied to study the influence of material parameters on serrate chip formation during high speed cutting process. The serrated chip formation during high speed machining was predicted. Of interests are the effects of thermal conductivity, specific heat and density. Results showed significant influence of these thermophysical parameters on the serrated chip phenomena, especially in the case of the density. Increasing thermal conductivity specific heat and density lead to a decreasing degree of segmentation. The influence of the thermal conductivity on the cutting force and the specific heat on maximum temperatures in the shear band is also discussed.

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

2010 ◽  
Vol 29-32 ◽  
pp. 1838-1843 ◽  
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.

Finite Element Simulation of Chip Formation during High-Speed Peripheral Milling of Hardened Mold Steel

2010 ◽  
Vol 443 ◽  
pp. 274-278 ◽  
Author(s):  
De Weng Tang ◽  
Cheng Yong Wang ◽  
Ying Ning Hu ◽  
Yue Xian Song
Keyword(s):  
Finite Element ◽  
Chip Formation ◽  
High Speed ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Peripheral Milling ◽  
Element Analysis ◽  
High Speed Milling ◽  
Element Simulation ◽  
The Finite Element Analysis

The modeling and simulation of chip formation during high speed milling of hardened mold steel are systematically studied by the Finite Element Analysis (FEA). The modified Johnson-Cook’s constitutive equation for hardened mold steel is introduced. Comparing to the experimental results, the simulated results of cutting force, chip morphology, effective stress and cutting temperature in deformation zones of high speed peripheral milling indicate good consistence and the models established can be used to accurately predict the behavior of hardened mold steel.

3D Finite Element Simulation of Inclined Cutting of Hardened 45 Steel

2014 ◽  
Vol 620 ◽  
pp. 104-109
Author(s):  
Guo He Li ◽  
Yu Jun Cai ◽  
Hui Yan Li
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Rake Angle ◽  
Cutting Depth ◽  
Flow Angle ◽  
3D Finite Element ◽  
High Speed Cutting ◽  
Chip Flow ◽  
Element Simulation ◽  
Deformation Coefficient

The research of the simulation for high speed cutting is usually based on 2D modeling by now, and the 3D simulation is few. Because the cutting process is a 3D deformation of workpiece, it's badly in need of the research on 3D finite element simulation of cutting process for further reveal the mechanism of high speed cutting. The 3D simulation of inclined cutting of hardened 45 steel (45HRC) is carried out base on ABAQUS. The forming process of serrated chip is simulated by adopting the Johnson-cook material modeling and separation criterion of shear failure. The change of chip morphology, chip flow angle and deformation coefficient of width under different rake angle and cutting depth are analyzed. The results show that the segment degree of chip becomes larger with the decrease of rake angle and increase of cutting depth. The chip flow angle is not effected by rake angle and its value is approximately equal to tool cutting edge inclination angle, an it increases with the increase of cutting depth. The deformation coefficient of width increase with the decrease of rake angle and increase of cutting depth.

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