Simulation of High-Speed Cutting Process Based on ABAQUS

2011 ◽  
Vol 230-232 ◽  
pp. 1221-1225 ◽  
Author(s):  
Xia Yu ◽  
Xu Yao Sun ◽  
Dan Ke Wei
Keyword(s):  
High Speed ◽  
Chip Morphology ◽  
Material Model ◽  
Rake Angle ◽  
Cutting Process ◽  
Fe Model ◽  
High Speed Cutting ◽  
Line Technology ◽  
Chip Separation ◽  
The Impact

Using the separation line technology, established a FE model of two-dimensional cutting process for AISI4340 steel and discussed some basic theory and pivotal questions associated with the simulation of cutting process including the Johnson-Cook material model, the contact model between tool and chip, criteria of chip separation and so on. In order to study the impact of tool rake angle on the chip morphology and the cutting forces, the high-speed cutting process for AISI 4340 steel was simulated based on ABAQUS software. Also, analyzed the influence of mesh azimuth on the chip morphology and its temperature distribution.

Predicting the High Speed Cutting Process of Titanium Alloy by Finite Element Method

2011 ◽  
Author(s):  
Xiangqin Zhang ◽  
Xueping Zhang ◽  
A. K. Srivastava
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Cutting Process ◽  
Fe Model ◽  
Dry Cutting ◽  
Friction Coefficients ◽  
Machining Conditions

To predict the cutting forces and cutting temperatures accurately in high speed dry cutting Ti-6Al-4V alloy, a Finite Element (FE) model is established based on ABAQUS. The tool-chip-work friction coefficients are calculated analytically using the measured cutting forces and chip morphology parameter obtained by conducting the orthogonal (2-D) machining tests. It reveals that the friction coefficients between tool-work are 3∼7 times larger than that between tool-chip, and the friction coefficients of tool-chip-work vary with feed rates. The analysis provides a better reference for the tool-work-chip friction coefficients than that given by literature empirically regardless of machining conditions. The FE model is capable of effectively simulating the high speed dry cutting process of Ti-6Al-4V alloy based on the modified Johnson-Cook model and tool-work-chip friction coefficients obtained analytically. The FE model is further validated in terms of predicted forces and the chip morphology. The predicted cutting force, thrust force and resultant force by the FE model agree well with the experimentally measured forces. The errors in terms of the predicted average value of chip pitch and the distance between chip valley and chip peak are smaller. The FE model further predicts the cutting temperature and residual stresses during high speed dry cutting of Ti-6Al-4V alloy. The maximum tool temperatures exist along the round tool edge, and the residual stress profiles along the machined surface are hook-shaped regardless of machining conditions.

Identification of Flow Stress Applicable for FEM Simulation of Orthogonal Cutting Process

2014 ◽  
Vol 625 ◽  
pp. 378-383 ◽  
Author(s):  
Norfariza Wahab ◽  
Yumi Inatsugu ◽  
Satoshi Kubota ◽  
Soo Young Kim ◽  
Hiroyuki Sasahara
Keyword(s):  
Flow Stress ◽  
Strain Rate ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Fem Simulation ◽  
Material Model ◽  
Cutting Process ◽  
Machining Parameters ◽  
High Speed Cutting ◽  
Cutting Test

Nowadays, numerical simulation technique is very popular to estimate and predict the machining parameters such as cutting forces, stresses distribution, temperature and tool wear. The objective of this study is to determine the 0.45%C steel (JIS S45C) flow stress value under high strain rate and temperature. The Johnson and Cook (JC) material model is used as a constitutive equation to describe the high speed cutting process. Compression test and orthogonal cutting test were carried out in order to obtain the required parameters in JC model. Inverse calculation method was used to determine the strain rate and temperature dependency parameter based on several cutting conditions. As a result, validity of verification of method was completed and the flow stress of S45C had been evaluated.

Multi-Scale Fe Modeling Inconel718 Machining Process and Crack Initiation of Brittle Particle

2012 ◽  
Vol 500 ◽  
pp. 574-579 ◽  
Author(s):  
Xiao Jin Xu ◽  
Li Qiang Ding ◽  
Xue Ping Zhang
Keyword(s):  
Crack Initiation ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Great Influence ◽  
Cutting Process ◽  
Machining Process ◽  
Fe Model ◽  
Multi Scale ◽  
Feed Force ◽  
The Impact

nconel718 is particle reinforced metal matrix composites widely applied in important fields. To evaluate the impact of particles on the machined subsurface in Inconel718 during high-speed machining operation, a multi-scale orthogonal cutting finite element (FE) model is established. A cohesive element technique is adopted to predict particle crack initiation process. The multi-scale FE model is validated with experimental data in terms of cutting forces and chip morphology. The simulation reveals that particle has a great influence on surface roughness and the feed force when particles are located in the sub-surface within the depths of 30μm, and the cutting process has less effect on the particle crack initiation when the particles in the depths of more than 40μm or deeper. The interaction effects generated from particle sizes in the same depth are investigated on the cutting process and particle crack initiation.

Simulation of High-Speed Cutting Using Deform 3D Software

2020 ◽  
Vol 299 ◽  
pp. 340-344
Author(s):  
Leonid Moiseevich Gurevich ◽  
Roman Novikov ◽  
Alexander Bannikov
Keyword(s):  
Software Package ◽  
High Speed ◽  
Rake Angle ◽  
Cutting Process ◽  
Work Piece ◽  
High Speed Cutting ◽  
3D Software ◽  
Deform 3D

The paper presents the result of the simulation of high-speed hot cutting process for ordinary and new saw geometry, using the Deform 3D software package. It was shown that the use of an additional side rake angle allows to controllably leave burr on one side of the work-piece only, and shift max stress from the saw gullets to the top of teeth.

Modeling of Tread Block Contact Mechanics Using Linear Viscoelastic Theory3

2008 ◽  
Vol 36 (3) ◽  
pp. 211-226 ◽  
Author(s):  
F. Liu ◽  
M. P. F. Sutcliffe ◽  
W. R. Graham
Keyword(s):  
High Speed ◽  
Slip Rate ◽  
Material Model ◽  
Contact Forces ◽  
Block Modeling ◽  
Rate Dependent ◽  
Linear Viscoelastic Material ◽  
Linear Viscoelastic ◽  
The Impact ◽  
Good Agreement

Abstract In an effort to understand the dynamic hub forces on road vehicles, an advanced free-rolling tire-model is being developed in which the tread blocks and tire belt are modeled separately. This paper presents the interim results for the tread block modeling. The finite element code ABAQUS/Explicit is used to predict the contact forces on the tread blocks based on a linear viscoelastic material model. Special attention is paid to investigating the forces on the tread blocks during the impact and release motions. A pressure and slip-rate-dependent frictional law is applied in the analysis. A simplified numerical model is also proposed where the tread blocks are discretized into linear viscoelastic spring elements. The results from both models are validated via experiments in a high-speed rolling test rig and found to be in good agreement.

The Application of FEA in High-Speed Cutting

2011 ◽  
Vol 287-290 ◽  
pp. 104-107
Author(s):  
Lian Qing Ji ◽  
Kun Liu
Keyword(s):  
High Speed ◽  
Feeding Rate ◽  
Cutting Tools ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Material Model ◽  
Friction Model ◽  
Cutting Depth ◽  
High Speed Cutting ◽  
Key Technologies

The history and application of the FEA are briefly presented in this paper. Several key technologies such as the building of material model, the establishment of the chip - tool friction model as well as meshing are described. Taking the high-speed cutting of titanium alloy (Ti - 10V - 2Fe - 3Al) as an example , reasonable cutting tools and cutting parameters are determinted by simulating the influences of cutting speed, cutting depth and feeding rate on the cutting parameters using FEA.

Using Image Analysis Techniques for Single Evaluation of the Chip Shrinkage Factor in Orthogonal Cutting Process

2012 ◽  
Vol 504-506 ◽  
pp. 1329-1334 ◽  
Author(s):  
Moises Batista ◽  
Madalina Calamaz ◽  
Franck Girot ◽  
Jorge Salguero ◽  
Mariano Marcos
Keyword(s):  
High Speed ◽  
Orthogonal Cutting ◽  
Rake Angle ◽  
Cutting Process ◽  
Shrinkage Factor ◽  
A Value ◽  
Chip Shrinkage ◽  
Chip Geometry ◽  
Image Analysis Techniques

The forces involved in a cutting process are related, for example, with the power consumption, with the final quality of the workpiece and with the chip geometry obtained, since these forces determine the compression experimented by the chip and therefore its final geometry. The orthogonal cutting process assisted with a High Speed Filmation (HSF) permit obtains a digital filmation of the process with high magnification. This filmation permits to obtain a measurement of the longitudinal changes produced in the chip. This deforms are related with the Shrinkage Factor, ζ. And in this case the Stabler hypothesis is enabled, by that using the shear angle and the rake angle is possible obtain a value of the Shrinkage Factor in a different conditions.

Influence of Cutting Conditions on the Width of Adiabatic Shear Bands: An Investigation Using Finite Element Simulation

2013 ◽  
Vol 820 ◽  
pp. 194-199
Author(s):  
Tao Cui ◽  
Hong Wei Zhao ◽  
Ye Tian ◽  
Chuang Liu
Keyword(s):  
High Speed ◽  
Shear Bands ◽  
Chip Thickness ◽  
Rake Angle ◽  
Adiabatic Shear ◽  
Adiabatic Shear Bands ◽  
High Speed Cutting ◽  
Model Combining ◽  
Cutting Velocity ◽  
Microstructure Prediction

In this paper, a novel model combining the microstructure prediction model and a modified constitutive model of the Johnson-Cook (JC) model was developed and embedded into FEM software via the user subroutine. The chip formation and microstructure evolution in high speed cutting of Ti-6Al-4V alloy were simulated. The results indicated that dynamic recrystallization mainly happened in adiabatic shear bands (ASBs), where the grain size had a big decline. Then FEM simulations were carried out to investigate the effect of cutting velocity, uncut chip thickness, and the rake angle on the ASBs width of the serrated chips. It can be concluded that the width of ASB increases with the increasing of cutting depth and cutting velocity, and decreases with the increasing of rake angle of the tool.

FE Modeling of the Three-Layer Human Carotid Artery Under Impact Loadings

2007 ◽  
Author(s):  
Aihong Zhao ◽  
Ken Digges ◽  
Mark Field ◽  
David Richens
Keyword(s):  
Finite Element ◽  
Carotid Artery ◽  
Model Simulation ◽  
Material Model ◽  
Element Model ◽  
Traumatic Rupture ◽  
Aortic Tissue ◽  
Fe Model ◽  
Arbitrary Lagrangian Eulerian ◽  
The Impact

Blunt traumatic rupture of the carotid artery is a rare but life threatening injury. The histology of the artery is key to understanding the aetiology of this injury. The carotid artery is composed of three layers known as the tunica intima, media, and adventitia, with distinct biomechanical properties. In order to examine the behaviour of the carotid artery under external load we have developed a three layer finite element model of this vessel. A rubber-like material model from LS-DYNA was selected for the FE model. The Arbitrary-Lagrangian Eulerian (ALE) approach was adopted to simulate the interaction between the fluid (blood) and the structure (carotid). To verify the FE model, the impact bending tests are simulated using this FE model. Simulation results agree with tests results well. Furthermore, the mechanical behaviour of carotid artery tissues under impact loading were revealed by the simulations. The results provide a basis for a more in-depth investigation of the carotid artery in vehicle crashes. In addition, it provides a basis for further work on aortic tissue finite element modeling.

Investigation of Surface Characteristics and Chip Morphology in High Speed Cutting of Inconel718 Based on SHPB System

2019 ◽  
Author(s):  
Zengqiang Wang ◽  
Zhanfei Zhang ◽  
Wenhu Wang ◽  
Ruisong Jiang ◽  
Kunyang Lin ◽  
...  
Keyword(s):  
Surface Roughness ◽  
High Speed ◽  
Split Hopkinson Pressure Bar ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Surface Profile ◽  
Chip Morphology ◽  
Depth Of Cut ◽  
Machined Surface ◽  
High Speed Cutting

Abstract High speed cutting (HSC) technology has the characteristics of high material removal rates and high machining precision. In order to study the relationships between chip morphology and machining surface characteristic in high speed cutting of superalloy Inconel718. High-speed orthogonal cutting experiment are carried out by used a high speed cutting device based on split Hopkinson pressure bar (SHPB). The specimen surfaces and collected chips were then detected with optical microscope, scanning electron microscope and three-dimensional surface profile measuring instrument. The results show that within the experimental parameters (cutting speed from 8–16m/s, depth of cut 0.1–0.5mm), the obtained chips are sawtooth chips and periodic micro-ripple appear on the machined surface. With the cutting speed increases, machining surface roughness is decreases from 1.4 to 0.99μm, and the amplitude of periodic ripples also decreases. With the cutting depth increases, the machining surface roughness increases from 0.96 to 5.12μm and surface topography becomes worse. With the increase of cutting speed and depth of cut, the chips are transform from continues sawtooth to sawtooth fragment. By comparing the frequency of surface ripples and sawtooth chips, it is found that they are highly consistent.

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