scholarly journals Numerical and experimental investigation of Johnson–Cook material models for aluminum (Al 6061-T6) alloy using orthogonal machining approach

2018 ◽  
Vol 10 (9) ◽  
pp. 168781401879779 ◽  
Author(s):  
Sohail Akram ◽  
Syed Husain Imran Jaffery ◽  
Mushtaq Khan ◽  
Muhammad Fahad ◽  
Aamir Mubashar ◽  
...  
Keyword(s):  
Coefficient Of Friction ◽  
Cutting Forces ◽  
High Speed ◽  
Material Model ◽  
Material Behavior ◽  
Experimental Results ◽  
Model Parameters ◽  
Al 6061 ◽  
Orthogonal Machining ◽  
Cutting Speeds

This research focuses on the study of the effects of processing conditions on the Johnson–Cook material model parameters for orthogonal machining of aluminum (Al 6061-T6) alloy. Two sets of parameters of Johnson–Cook material model describing material behavior of Al 6061-T6 were investigated by comparing cutting forces and chip morphology. A two-dimensional finite element model was developed and validated with the experimental results published literature. Cutting tests were conducted at low-, medium-, and high-speed cutting speeds. Chip formation and cutting forces were compared with the numerical model. A novel technique of cutting force measurement using power meter was also validated. It was found that the cutting forces decrease at higher cutting speeds as compared to the low and medium cutting speeds. The poor prediction of cutting forces by Johnson–Cook model at higher cutting speeds and feed rates showed the existence of a material behavior that does not exist at lower or medium cutting speeds. Two factors were considered responsible for the change in cutting forces at higher cutting speeds: change in coefficient of friction and thermal softening. The results obtained through numerical investigations after incorporated changes in coefficient of friction showed a good agreement with the experimental results.

Cutting Forces and Vibration of Pockets Corner by High Speed Milling

2009 ◽  
Vol 69-70 ◽  
pp. 59-63 ◽  
Author(s):  
Cheng Yong Wang ◽  
De Weng Tang ◽  
Zhe Qin ◽  
Z.G. Chen ◽  
Ying Ning Hu ◽  
...  
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Sudden Change ◽  
Poor Quality ◽  
Depth Of Cut ◽  
High Speed Milling ◽  
Radial Depth ◽  
Cutting Direction ◽  
Cutting Speeds

When the pocket in die and mould is machined by high speed milling (HSM), the cutting forces increase and vibration fluctuates at the pocket corner because of the sudden change of cutting direction in general. It will cause serious wear and possible breakage of cutting tool, and poor quality of parts. By means of experiments, the cutting forces and vibration at the pocket corner with different HSM conditions are measured. The results show that the sharper pocket corner, higher cutting speeds, larger feed rate per tooth and radial depth of cut, will result in increasing of cutting forces and vibration amplitude. Thus, it will lead to be unstable during the process of high speed milling pocket corner.

Ultra-High-Speed Machining: A Review and an Analysis of Cutting Forces

1973 ◽  
Vol 187 (1) ◽  
pp. 625-634 ◽  
Author(s):  
G. Arndt
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Physical Factors ◽  
High Speed Machining ◽  
Work Related ◽  
Rate Dependent ◽  
High Speeds ◽  
Ultra High Speed ◽  
Very High ◽  
Cutting Speeds

As part of the search for a new cutting mechanism, a few largely empirical investigations into ultra-high-speed machining (velocity greater than 500 ft/s) have been performed in the past. A comprehensive review of this and other work related to machining at very high cutting speeds is presented and the physical factors predominating in UHSM are discussed. As a consequence of this a new theory of cutting forces at ultra-high speeds is presented, based on inertia and temperature effects, adiabatic shear, and strain-rate dependent yield stress. This theory shows that workpiece properties greatly influence force behaviour, the latter determining the feasibility of machining at ultra-high speeds.

Analysis of crush-damaged carbon-fiber-reinforced-polymer (CFRP) composites with optimization-assisted post-peak-stress modeling

2020 ◽  
pp. 002199832095770
Author(s):  
Sheng Dong ◽  
Lars Gräning ◽  
Kelly Carney ◽  
Allen Sheldon
Keyword(s):  
Cross Sections ◽  
Peak Stress ◽  
Material Model ◽  
Material Behavior ◽  
Engineering Practice ◽  
Model Parameters ◽  
Optimization Strategy ◽  
Damage Models ◽  
Cfrp Composites ◽  
Force Time

In the presented effort, layered CFRP composites samples with differing thicknesses and cross-sections are manufactured and crushed under quasi-static loading conditions. Simulation of the crushes are conducted using traditional continuum mechanics damage models. Parameters are proposed to represent the post peak-stress material behavior including the residual strengths of the fiber and matrix, as well the ultimate strain for deletion of composite elements. This paper presents a systematic approach to identify optimal values for these post peak-stress parameters based on a methodology incorporating CAE models and numerical optimization. An adaptive meta-model based global optimization strategy, with the objective of matching the force-time characteristics of multiple crush experiments simultaneously, has been established to quantify the values of the CFRP’s post peak-stress degradation and erosion material model parameters through calibration. Using two separate test configurations for optimization, a set of values for those parameters are determined. This parameter set is shown to successfully predict the response of additional test cases, including matching of force-displacement curves and crushing modes. The resulting composite crush simulations show a good quantitative as well as qualitative agreement between simulations and experiments to a degree that is difficult to be achieved solely with previous engineering practice.

Ultra-High-Speed Machining: A Review and an Analysis of Cutting Forces

1973 ◽  
Vol 187 (1) ◽  
pp. 625-634 ◽  
Author(s):  
G. Arndt
Keyword(s):  
Cutting Forces ◽  
High Speed ◽  
Physical Factors ◽  
High Speed Machining ◽  
Work Related ◽  
Rate Dependent ◽  
High Speeds ◽  
Ultra High Speed ◽  
Very High ◽  
Cutting Speeds

As part of the search for a new cutting mechanism, a few largely empirical investigations into ultra-high-speed machining (velocity greater than 500 ft/s) have been performed in the past. A comprehensive review of this and other work related to machining at very high cutting speeds is presented and the physical factors predominating in UHSM are discussed. As a consequence of this a new theory of cutting forces at ultra-high speeds is presented, based on inertia and temperature effects, adiabatic shear, and strain-rate dependent yield stress. This theory shows that workpiece properties greatly influence force behaviour, the latter determining the feasibility of machining at ultra-high speeds.

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.

scholarly journals Taguchi parametric study on the radial and tangential cutting forces in Dry High Speed Machining (DHSM)

10.30544/472 ◽  
2020 ◽  
Vol 26 (3) ◽  
pp. 303-316
Author(s):  
M. Hatami ◽  
H. Safari
Keyword(s):  
Titanium Alloy ◽  
Cutting Force ◽  
Feed Rate ◽  
Parametric Study ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Tools ◽  
High Speed Machining ◽  
Cutting Speeds

In this paper, L8 Taguchi array is applied to find the most important parameters effects on the radial and tangential cutting forces of a Ti–6Al-4V ELI titanium alloy in dry high speed machining (DHSM). The experiments are performed in four cutting speeds of 150, 200, 250, and 300 m/min and two feed rates of 0.03 and 0.06 mm/rev. Also, two cutting tools in types of XOMX090308TR-ME06 of uncoated (H25) and TiAlN+TiN coated (F40M) are used. Results confirm that to minimize the resultant cutting force and radial cutting force, utilizing the lower feed rate and higher cutting speeds were considered as the best levels of factors to reach to its goal.

Machining Simulation of Ductile Iron and its Constituents: Part I — Estimation of Material Model Parameters and Their Validation

2001 ◽  
Author(s):  
L. Chuzhoy ◽  
R. E. DeVor ◽  
S. G. Kapoor ◽  
A. J. Beaudoin ◽  
D. J. Bammann
Keyword(s):  
Ductile Iron ◽  
Heterogeneous Materials ◽  
Material Model ◽  
Material Behavior ◽  
Model Parameters ◽  
Notched Specimens ◽  
Reverse Loading ◽  
Level Model ◽  
Validation Stage ◽  
Good Agreement

Abstract A microstructure-level simulation model was recently developed to characterize machining behavior of heterogeneous materials. During machining of heterogeneous materials such as cast iron, the material around the machining-affected zone undergoes reverse loading, which manifests itself in permanent material softening. In addition, cracks are formed below and ahead of the tool. To accurately simulate machining of heterogeneous materials the microstructure-level model has to reproduce the effect of material softening on reverse loading (MSRL effect) and material damage. This paper describes procedures used to calculate the material behavior parameters for the aforementioned phenomena. To calculate the parameters associated with the MSRL effect, uniaxial reverse loading experiments and simulations were conducted using individual constituents of ductile iron. The material model was validated with reverse loading experiments of ductile iron specimens. To determine the parameters associated with fracture of each constituent, experiments and simulation of notched specimens are performed. During the validation stage, response of simulated ductile iron was in good agreement with the experimental data.

Machining Simulation of Ductile Iron and Its Constituents, Part 1: Estimation of Material Model Parameters and Their Validation

2003 ◽  
Vol 125 (2) ◽  
pp. 181-191 ◽  
Author(s):  
L. Chuzhoy ◽  
R. E. DeVor ◽  
S. G. Kapoor ◽  
A. J. Beaudoin ◽  
D. J. Bammann
Keyword(s):  
Ductile Iron ◽  
Heterogeneous Materials ◽  
Material Model ◽  
Material Behavior ◽  
Model Parameters ◽  
Notched Specimens ◽  
Reverse Loading ◽  
Level Model ◽  
Validation Stage ◽  
Good Agreement

A microstructure-level simulation model was recently developed to characterize machining behavior of heterogeneous materials. During machining of heterogeneous materials such as cast iron, the material around the machining-affected zone undergoes reverse loading, which manifests itself in permanent material softening. In addition, cracks are formed below and ahead of the tool. To accurately simulate machining of heterogeneous materials the microstructure-level model has to reproduce the effect of material softening on reverse loading (MSRL effect) and material damage. This paper describes procedures used to calculate the material behavior parameters for the aforementioned phenomena. To calculate the parameters associated with the MSRL effect, uniaxial reverse loading experiments and simulations were conducted using individual constituents of ductile iron. The material model was validated with reverse loading experiments of ductile iron specimens. To determine the parameters associated with fracture of each constituent, experiments and simulation of notched specimens are performed. During the validation stage, response of simulated ductile iron was in good agreement with the experimental data.

Prediction of High Speed Machining Cutting Forces Using a Variable Flow Stress Machining Theory

2011 ◽  
Vol 188 ◽  
pp. 128-133 ◽  
Author(s):  
Philip Mathew
Keyword(s):  
Flow Stress ◽  
Cutting Forces ◽  
High Speed ◽  
Experimental Results ◽  
The Other ◽  
Cutting Conditions ◽  
High Speed Machining ◽  
Variable Flow ◽  
Machining Conditions

A variable flow stress machining theory is described where it is used to predict the cutting forces associated with High Speed Machining (HSM) process. The predicted and experimental results for different materials and different cutting conditions are presented and compared and it is shown that the theory developed is capable of predicting the cutting forces and the other parameters associated with the HSM process. The extension of the theory to HSM has been successful within the machining conditions presented here in this paper. Further work is necessary to improve this theory further.

Tensile Behavior of 82/182 Filler, Butter and Heat-Affected-Zones in a 508 LAS - 316 SS Dissimilar Weld: Tensile Test, Material Model and Finite Element Model Validation

2019 ◽  
Author(s):  
Subhasish Mohanty ◽  
Joseph Listwan ◽  
Saurindranath Majumdar ◽  
Krishnamurti Natesan
Keyword(s):  
Finite Element ◽  
Tensile Test ◽  
Low Cycle Fatigue ◽  
Material Model ◽  
Material Behavior ◽  
Test Material ◽  
Model Parameters ◽  
Fe Model ◽  
Component Level ◽  
Dissimilar Weld

Abstract In this paper we present the room temperature tensile test results for 82/182 Filler, Butter Weld and Heat-Affected-Zone in a 508 LAS − 316 SS Dissimilar Weld (DW). Also we present the associated tensile properties and material hardening model parameters; those can be used for future component level stress analysis modes. In addition, we present the finite element (FE) model of the uniaxial DW tensile-test specimens to validate the accuracy of the estimated material model parameters. Through the FE model results, we also explain the importance of various offset strain yield stress in capturing the material behavior in a mechanistic (using FE) modeling approach particularly while modeling the plasticity driven low-strain-amplitude low-cycle-fatigue damage of a structural component.

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