scholarly journals Influences of Cutting Speed and Material Constitutive Models on Chip Formation and their Effects on the Results of Ti6Al4V Orthogonal Cutting Simulation

2021 ◽  
Author(s):  
Nithyaraaj Kugalur-Palanisamy ◽  
Edouard Rivière-Lorphèvre ◽  
Pedro-José Arrazola ◽  
François Ducobu
Keyword(s):  
Finite Element ◽  
Constitutive Model ◽  
Chip Formation ◽  
Orthogonal Cutting ◽  
Constitutive Models ◽  
Cutting Speed ◽  
Element Model ◽  
Cutting Process ◽  
Machine Material ◽  
On Chip

The highly used Ti6Al4V alloy is a well know hard-to-machine material. The modelling of orthogonal cutting process of Ti6Al4V attract the interest of many researchers as it often generates serrated chips. The purpose of this paper is to show the significant influence of cutting speed on chip formation during orthogonal cutting of Ti6Al4V along with different material constitutive models. Finite element analyses for chip formation are conducted for different cutting speeds and are investigated with well-known Johnson-Cook constitutive model, a modified Johnson–Cook model known as Hyperbolic Tangent (TANH) model that emphasizes the strain softening behavior and modified Johnson-Cook constitutive model that consider temperature dependent strain hardening factor. A 2D Lagrangian finite element model is adopted for the simulation of the orthogonal cutting process and the results from the simulations such as calculated forces, chip morphologies are analyzed and are compared with the experimental results to highlight the differences. The results analysis shows that, the temperature in the secondary deformation zone is directly proportional to the cutting speed.

Finite Element Simulation of Quick – Stop Experiments for Better Understanding of Chip Formation in Grinding

2011 ◽  
Vol 223 ◽  
pp. 764-773 ◽  
Author(s):  
Hans Werner Hoffmeister ◽  
Arne Gerdes
Keyword(s):  
Finite Element ◽  
Chip Formation ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Element Model ◽  
Rake Angle ◽  
Grinding Process ◽  
Workpiece Material ◽  
Element Simulation ◽  
Single Grain

Several authors have previously simulated chip formation and their behaviour at the orthogonal cutting process. In contrast the chip formation for grinding was less investigated. This paper introduces a quick-stop device which allows easy investigation of the chip formation for the grinding process. For this process a workpiece forced by compressed air is shot against a single grain diamond with a large negative rake angle. Cutting forces were measured with a piezo electric sensor and discussed for a cutting speed range from 10m/s up to 30m/s. In Abaqus/Explicit a lagrangian formulation based finite element model was built to describe the chip formation for the grinding process. Chip formation, stress and heat distribution in the workpiece material can be calculated by this simulation model. The material behaviour was described with the Johnson Cook law. The simulation results show a good correlation compared to the quick stop experiments. All in all this simulation leads to a better understanding of the chip formation during grinding.

Finite Element and Experimental Analysis of Edge Defects Formation during Orthogonal Cutting of SiCp/Al Composites

2012 ◽  
Vol 500 ◽  
pp. 146-151 ◽  
Author(s):  
Ning Hou ◽  
Li Zhou ◽  
Shu Tao Huang ◽  
Li Fu Xu
Keyword(s):  
Finite Element ◽  
Chip Formation ◽  
Defect Formation ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Rake Angle ◽  
Critical Transition ◽  
Cutting Depth ◽  
Edge Defect ◽  
Edge Defects

In this paper, a finite element method was used to dynamically simulate the process of the edge defects formation during orthogonal cutting SiCp/Al composites. The influence of the cutting speed, cutting depth and rake angle of the PCD insert on the size of the edge defects have been investigated by using scanning electron. According to the simulated results, it can be provided that the cutting layer material has an effect on transfer stress and hinder the chip formation in the critical transition stage, and the critical transition point and distance are defined in this stage. The negative shear phenomenon is found when the chip transit to the edge defects in the flexure deformation stage, so the process of the chip formation is the basis of the edge defects formation. In addition, the relationship between the nucleation and propagation direction of the crack and the variation of the edge defect shape on the workpiece was investigated by theory, and it found that the negative shear angle formation is the primary cause of the edge defect formation. A mixed mode crack is found in the crack propagation stage. The sizes of edge defects were measured by the experiment and simulation, and the edge defect size decrease with the increasing of tool rake angle, while increase with increasing cutting depth and cutting speed.

Cutting Characteristics of Sugarcane in Terms of Physical and Chemical Properties

2020 ◽  
Vol 63 (4) ◽  
pp. 1007-1017
Author(s):  
Luxin Xie ◽  
Jun Wang ◽  
Shaoming Cheng ◽  
Dongdong Du
Keyword(s):  
Finite Element ◽  
Chemical Composition ◽  
Correlation Analysis ◽  
Finite Element Model ◽  
Physical Properties ◽  
Cutting Force ◽  
Single Point ◽  
Cutting Speed ◽  
Element Model ◽  
Cutting Process

HighlightsThe cutting mechanism of sugarcane stalks using single-point clamping was analyzed.Physical properties, chemical composition, and maximum cutting force of sugarcane were explored.Strong and complicated correlations between physical properties and chemical composition were established.Stress distributions in sugarcane stalks and the cutting blade were predicted using a finite element model.Abstract. Research on the cutting characteristics of sugarcane stalks is of great significance to improve harvest mechanization. In this study, perpendicular cutting of sugarcane stalks at six different nodes and internodes along the stalk was tested using a single-point clamping method at three cutting speeds (30, 40, and 50 mm min-1). The physical properties and chemical composition were also measured. At the 50 mm min-1 cutting speed, the maximum cutting forces at nodes and internodes upward along the stalk decreased gradually from 810 to 530 N and from 600 to 440 N, respectively. The maximum cutting force was positively correlated with the cutting speed at the same position. Differences in the microstructures of nodes, internodes, and epidermis were revealed by SEM micrographs. The physical properties and chemical composition of the stalks showed significant correlations. Correlation analysis was used to clarify the complicated interrelationships among these independent variables and revealed the interacting mechanism between physical properties and chemical composition. A finite element model was established to simulate the sugarcane cutting process. Results showed that the simulated cutting resistance of the blade was close to that in the experiments. The maximum Von Mises stress of the sugarcane stalk and blade in the cutting process were about 23.34 and 254.17 MPa, respectively. The results of this study provide guidance for designing and optimizing base-cutters of sugarcane harvesters and similar cutting equipment. Keywords: Chemical composition, Correlation analysis, Cutting characteristics, Microstructure, Physical properties, Simulation.

Crystallographic effects during micromachining — A finite-element model

2015 ◽  
Vol 29 (22) ◽  
pp. 1550119
Author(s):  
Shin-Hyung Song ◽  
Woo Chun Choi
Keyword(s):  
Finite Element ◽  
Finite Element Model ◽  
Chip Formation ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Material Behavior ◽  
Face Centered Cubic ◽  
Work Material ◽  
User Material Subroutine ◽  
Crystallographic Orientations

Mechanical micromachining is a powerful and effective way for manufacturing small sized machine parts. Even though the micromachining process is similar to the traditional machining, the material behavior during the process is much different. In particular, many researchers report that the basic mechanics of the work material is affected by microstructures and their crystallographic orientations. For example, crystallographic orientations of the work material have significant influence on force response, chip formation and surface finish. In order to thoroughly understand the effect of crystallographic orientations on the micromachining process, finite-element model (FEM) simulating orthogonal cutting process of single crystallographic material was presented. For modeling the work material, rate sensitive single crystal plasticity of face-centered cubic (FCC) crystal was implemented. For the chip formation during the simulation, element deletion technique was used. The simulation model is developed using ABAQUS/explicit with user material subroutine via user material subroutine (VUMAT). Simulations showed that variation of the specific cutting energy at different crystallographic orientations of work material shows significant anisotropy. The developed FEM model can be a useful prediction tool of micromachining of crystalline materials.

FEA Simulation of the Influence of Cutting Parameters on Serrated Chip Formation in Machining Titanium Alloy Ti-6Al-4V

2012 ◽  
Vol 500 ◽  
pp. 152-156
Author(s):  
Zeng Hui Jiang ◽  
Ji Lu Feng ◽  
Xiao Ye Deng
Keyword(s):  
Titanium Alloy ◽  
Chip Formation ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Element Model ◽  
Serrated Chip ◽  
Wide Range ◽  
Serrated Chip Formation ◽  
Fea Simulation

A finite element model of a two dimensional orthogonal cutting process is developed. The simulation uses standard finite software is able to solve complex thermo-mechanical problems. A thermo-visco-plastic model for the machined material and a rigid cutting tool were assumed. One of the main characteristic of titanium alloy is serrated shape for a wide range of cutting conditions. In order to understand the influence of cutting parameters on the chip formation when machining titanium alloy Ti-6Al-4V. The influence of the cutting speed,the cutting depth and the feed on the chip shape giving rise to segmented chips by strain localisation is respectively discussed.

3D Finite Element Modeling of the Machining of Ti6Al4V Alloys

2011 ◽  
Vol 189-193 ◽  
pp. 1926-1929 ◽  
Author(s):  
Ji Hong Yang ◽  
Shou Jin Sun ◽  
Milan Brandt ◽  
Wen Yi Yan
Keyword(s):  
Finite Element ◽  
Chip Formation ◽  
Element Model ◽  
Cutting Process ◽  
Temperature Fields ◽  
Contact Friction ◽  
Dynamic Effects ◽  
3D Finite Element ◽  
Mechanical Coupling ◽  
Damage Law

A 3D finite element model of the machining of Ti6Al4V alloy has been developed. This model is able to simulate the formation of continuous or discontinuous chips during the cutting process that depends on the cutting conditions. In this model, the yield stress is considered as a function of the strain, the strain rate and the temperature. The dynamic effects, thermo-mechanical coupling, constitutive damage law and contact friction are taken into account. The stresses and temperature fields, chip formation and tool forces are obtained at different stages of the cutting process.

Mechanism of Chip Deformation in Orthogonal Cutting the Wheel Steel

2008 ◽  
Vol 375-376 ◽  
pp. 26-30
Author(s):  
Kai Xue ◽  
Xiang Ming Xu ◽  
Gang Liu ◽  
Ming Chen
Keyword(s):  
Chip Formation ◽  
Feed Rate ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Cutting Parameters ◽  
Wheel Steel ◽  
Tool Geometry ◽  
Orthogonal Turning ◽  
On Chip

The chip formation and morphology are definitely affected by tool geometry and cutting parameters such as cutting speed, feed rate, and depth of cutting. An experiment investigation was presented to study the influence of tool geometry on chip morphology, and to clarify the effect of different cutting parameters on chip deformation in orthogonal turning the wheel steel. The result obtained in this study showed that tool geometry affected the chip morphology significantly; cutting speed was the most contributive factor in forming saw-tooth chip.

A FEM and Experimental Study of Chip Formation in Orthogonal Cutting of Superalloy GH80A

2009 ◽  
Vol 626-627 ◽  
pp. 663-668
Author(s):  
Jun Li Li ◽  
Ming Chen ◽  
Bin Rong
Keyword(s):  
Chip Formation ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Rake Angle ◽  
Cutting Process ◽  
High Yield ◽  
Isotropic Model ◽  
On Chip ◽  
As Stress

The nickel-based superalloy GH80A has been widely used in kinds of aeronautical key structures because of its high yield stress and anti-fatigue performance at high temperature. However, it is also a typical difficult-to-cut material. In order to improve cutting process, kinds of methods have been applied to study cutting process including experimental approach and finite element method (FEM). In this paper, a comparison of chip formation is carried out between traditional Johnson-Cook (JC) model and Isotropic model. Besides, effects of tool rake angle and friction coefficient on chip formation are investigated by Isotropic model. FEM predicated results such as stress and cutting temperature are also analyzed. Relative turning tests are performed and comparison of chip morphology between FEM and experiment is carried out.

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