Identification and Validation of Marusich’s Constitutive Law for Finite Element Modeling of High Speed Machining

2014 ◽  
Author(s):  
Walid Jomaa ◽  
Monzer Daoud ◽  
Victor Songmene ◽  
Philippe Bocher ◽  
Jean-François Châtelain
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Chip Morphology ◽  
Material Model ◽  
Element Model ◽  
Contact Length ◽  
Constitutive Law ◽  
High Speed Machining ◽  
Orthogonal Machining ◽  
Deform 2D

This study aims to identify the coefficients of Marusich’s constitutive equation (MCE) for the aluminum AA7075-T651. Material constants were identified inversely form orthogonal machining tests and from dynamic tests. The proposed material model was successfully implemented in a finite element model (FEM) to simulate the high speed machining of the aluminum AA7075-T6. Deform 2D® software was used. A reasonable agreement between predictions and experiments was obtained. The comparison was based on cutting forces, chip morphology, and tool/chip contact length.

Finite Element Analysis of the Effects of Coated Tool on High Speed Orthogonal Machining

2008 ◽  
Vol 392-394 ◽  
pp. 879-883
Author(s):  
Hui Xia Liu ◽  
H. Yan ◽  
Xiao Wang ◽  
Shu Bin Lu ◽  
K. Yang ◽  
...  
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
High Speed ◽  
Finite Element Models ◽  
Finite Element Code ◽  
Element Analysis ◽  
Orthogonal Machining ◽  
Coated Tool ◽  
Deform 2D ◽  
Updated Lagrangian

Two 3-D finite element models of coated tool and uncoated tool were established using the finite element code DEFORM-2D based on the updated Lagrangian formula. And their machinability on high speed orthogonal machining was simulated and compared. The investigation results indicate that the coated tool has higher surface temperature and lower inside temperature compared with the uncoated tool. Moreover, the cutting forces of the model using coated tool are lower than that using uncoated tool.

The role of material model in the finite element simulation of high-speed machining of Ti6Al4V

2016 ◽  
Vol 230 (17) ◽  
pp. 2959-2967 ◽  
Author(s):  
Chong-Yang Gao ◽  
Liang-Chi Zhang ◽  
Peng-Hui Liu
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
High Speed ◽  
Material Model ◽  
Machining Process ◽  
High Speed Machining ◽  
Serrated Chip ◽  
Finite Element Program ◽  
Element Simulation ◽  
Improved Model

This paper provides a comprehensive assessment on some commonly used thermo-viscoplastic constitutive models of metallic materials during severe plastic deformation at high-strain rates. An hcp model previously established by us was improved in this paper to enhance its predictability by incorporating the key saturation characteristic of strain hardening. A compensation-based stress-updating algorithm was also developed to introduce the new hcp model into a finite element program. The improved model with the developed algorithm was then applied in finite element simulation to investigate the high-speed machining of Ti6Al4V. It was found that by using different material models, the simulated results of cutting forces, serrated chip morphologies, and residual stresses can be different too and that the improved model proposed in this paper can be applied to simulate the titanium alloy machining process more reliably due to its physical basis when compared with some other empirical Johnson–Cook models.

Modal Analysis of BT Spindle-Toolholder Interface Based on Abaqus/Standard

2013 ◽  
Vol 662 ◽  
pp. 632-636
Author(s):  
Yong Sheng Zhao ◽  
Jing Yang ◽  
Xiao Lei Song ◽  
Zi Jun Qi
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Modal Analysis ◽  
Dynamic Characteristics ◽  
High Speed ◽  
Element Model ◽  
Contact Theory ◽  
High Speed Machining ◽  
The Finite Element Model

The quality of high speed machining is directly related to dynamic characteristics of spindle-toolholder interface. The paper established normal and tangential interactions of BT spindle-toolholder interface based on finite element contact theory, and analysed free modal in Abaqus/Standard. Then the result was compared with the experimental modal analysis. It shows that the finite element model is effective and could be applied in the future dynamic study of high-speed spindle system.

3D Finite Element Modeling of High Speed Machining

2012 ◽  
pp. 178-196
Author(s):  
A.P. Markopoulos ◽  
K. Kantzavelos ◽  
N.I. Galanis ◽  
D.E. Manolakos
Keyword(s):  
Finite Element ◽  
Experimental Work ◽  
High Speed ◽  
Three Dimensional ◽  
Chip Morphology ◽  
Third Wave ◽  
Machining Parameters ◽  
High Speed Machining ◽  
Morphology Model ◽  
Coated Carbide

This paper presents simulation of High Speed Machining of steel with coated carbide tools. More specifically, Third Wave Systems AdvantEdge commercial Finite Element Method code is employed in order to present turning models, under various machining conditions. As a novelty, the proposed models for High Speed Machining of steel are three-dimensional and are able to provide predictions on cutting forces, tool and workpiece temperatures, chip formation, and chip morphology. Model validation is achieved through experimental work carried out under the same conditions as the ones used in modeling. For the experimental work, the principles for design of experiment were used in order to minimize the required amount of experiments and obtain useful results at the same time. Furthermore, a Taguchi analysis is carried out based on the results. The analysis indicates that there is a good agreement between experiment and modeling, and the proposed models can be further employed for the prediction of a range of machining parameters, under similar conditions.

A Comparative Study of High Speed Orthogonal Turning of AISI4340 by Three Different Finite Element Models

2013 ◽  
Vol 589-590 ◽  
pp. 111-116
Author(s):  
Tao Wang ◽  
Li Jing Xie ◽  
Xi Bin Wang
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Chip Morphology ◽  
Finite Element Models ◽  
Feed Force ◽  
Orthogonal Turning ◽  
Deform 2D ◽  
Explicit Dynamic ◽  
Chip Separation

The aim of this paper is to compare the predicting ability of the orthogonal cutting models developed by three commonly used finite element softwares, namely commercial explicit dynamic code Abaqus/explicit, Thirdwave AdvantEdge and implicit finite element codes Deform 2D. In all proposed models, the chip formation was simulated through adaptive remeshing and plastic flow of work material around the round edge of the cutting tool. Therefore, there was no need for a chip separation criterion which made the physical process simulation more realistically. Predicted cutting, feed force and shear angle were compared with experimental results. In addition, the effect of friction coefficient on the chip morphology was investigated as well.

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.

scholarly journals Dynamic Recrystallization Observed at the Tool/Chip Interface in Machining

2015 ◽  
Vol 651-653 ◽  
pp. 1223-1228
Author(s):  
Yannick Senecaut ◽  
Michel Watremez ◽  
Julien Brocail ◽  
Laurence Fouilland-Paillé ◽  
Laurent Dubar
Keyword(s):  
Finite Element ◽  
Dynamic Recrystallization ◽  
Finite Element Model ◽  
Rheological Behavior ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Numerical Results ◽  
Constitutive Law ◽  
Rheological Models

In numerical approaches for high speed machining, the rheological behavior of machined materials is usually described by a Johnson Cook law. However, studies have shown that dynamic recrystallization phenomena appear during machining in the tool/chip interface. The Johnson Cook constitutive law does not include such phenomena. Thus, specific rheological models based on metallurgy are introduced to consider these dynamic recrystallization phenomena. Two empirical models proposed by Kim et al. (2003) and Lurdos (2008) are investigated in machining modeling. A two-dimensional finite element model of orthogonal cutting, using an Arbitrary Lagrangian-Eulerian (ALE) formulation, is developed with the Abaqus/explicit software. Specific rheological models are implemented in the calculation code thanks to a subroutine. This finite element model can then predict chip formation, interfacial temperatures, chip-tool contact length, cutting forces and chip thickness with also and especially the recrystallized area. New specific experiments on an orthogonal cutting test bench are conducted on AISI 1045 steel specimens with an uncoated carbide tool. Many tests are performed and results are focused on total chip thicknesses and recrystallized chip thicknesses. Finally, compared to numerical results got with a Johnson Cook law, numerical results obtained using specific rheological models to take into account dynamic recrystallization phenomena are very close to experimental results. This work shows also the influence of rheological behavior laws on predicted results in the modeling of high speed modeling.

Finite Element Simulation of Extremely High Speed Machining of Ti6Al4V Alloy

2011 ◽  
Vol 141 ◽  
pp. 293-297 ◽  
Author(s):  
Yang Tan ◽  
Yi Lin Chi ◽  
Ya Yu Huang ◽  
Ting Qiang Yao
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Void Nucleation ◽  
Chip Morphology ◽  
Ti6al4v Alloy ◽  
Material Behavior ◽  
Fracture Mechanisms ◽  
High Speed Machining ◽  
Damage Initiation ◽  
Damage And Fracture

The finite element modeling and simulation of extremely high speed machining of Ti6Al4V alloy are presented in the paper. The Johnson-Cook’s constitutive model is used to describe the material behavior. The Johnson-Cook damage initiation criterion is used to predict the onset of damage due to void nucleation in ductile fracture. A damage evaluation law based on plastic strain energy and a fracture criterion combining the effect of different fracture mechanisms are proposed to model the progressive damage and fracture, respectively. Simulation results show that the predicted chip morphology agrees well with the experimental one. The distribution of temperature and specific cutting force are discussed later.

Tool-Chip Friction and Two-Dimensional Numerical Simulation Analysis of High-Speed Milling AISI304

2015 ◽  
Vol 1089 ◽  
pp. 377-380
Author(s):  
Lin Lin Guo ◽  
Guang Hui Li ◽  
Ning Xia Yin ◽  
Guang Yu Tan
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Simulation Analysis ◽  
Chip Morphology ◽  
Element Model ◽  
Simulation Method ◽  
State Theory ◽  
Friction Model ◽  
Two Dimensional ◽  
High Speed Milling

The physical friction system model was established between the tool and the chip based on the analysis of tri-bological behavior of high speed milling process of the end mill. The finite element simulation method was employed to study the tool-chip friction model, and the two-dimensional(2D) finite element model of milling was created. The numerical results revealed the chip morphology, stress and temperature distribution of the tool-chip contact surface. The tool temperature field distribution provided supports for tool-chip friction state theory and the 3D milling model.

Finite Element Modeling for High Speed Machining of Ti-6Al-4V Using ALE Boundary Technology

2011 ◽  
Vol 66-68 ◽  
pp. 1509-1514
Author(s):  
Dong Lu ◽  
Ming Ming Yang ◽  
Hong Fu Huang ◽  
Xiao Hong Zhong
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
High Speed ◽  
Element Model ◽  
Machining Process ◽  
Computational Time ◽  
High Speed Machining ◽  
Tool Edge Radius ◽  
Edge Radius ◽  
Tool Edge

A finite element model of HSM (High Speed Machining) process of Ti6Al4V was developed with Abaqus 6.10. The flow stress of Ti6Al4V is taken as a function of strain, strain rate and temperature. Considering the fact that the tool edge radius is relatively large in HSM of Ti6Al4V and significantly influences the mechanical behaviour, thus a new Arbitrary Lagrangian-Eulerian (ALE) boundary technology was incorporated into the finite element model to simulate the flowing material around the tool edge.The adoption of ALE boundary technology could avoid using the traditional chip separation criterias and element deletion method in the model, which at the same time results in the less excessive element distortion and computational time in comparison with traditional finite element models of cutting process. The simulation results of Cutting force and temperature close to the experimental values in an acceptable range could be obtained and a stagnant zone in front of the tool edge was successfully observed in this new developed model with large tool edge radius.

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