Prediction of Adiabatic Shear Critical Cutting Conditions of hardened AISI 1045 Steel with Different Hardness

2013 ◽  
Vol 589-590 ◽  
pp. 134-139
Author(s):  
Guo He Li ◽  
Yu Jun Cai ◽  
Hou Jun Qi
Keyword(s):  
Model Building ◽  
Orthogonal Cutting ◽  
Adiabatic Shear ◽  
Cutting Conditions ◽  
Constitutive Relationship ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Relationship Of ◽  
1045 Steel ◽  
Cutting Experiments

A method for building the constitutive relationship based on the J-C model and hardness is presented through considering the influence of hardness on the yield strength and the tensile strength. A constitutive relationship of hardened AISI 1045 is built by this method and the adiabatic shear critical cutting conditions of three kinds of hardness AISI 1045 steel are prediction through a model building by the linear pertubation analysis which considering the influence of compression stress of the primary shear zone, the cutting conditions and the constitutive relationship. For proving the prediction results, some orthogonal cutting experiments are performed to get the critical cutting conditions of adiabatic shear. The comparison shows that the prediction results are consistent with that of experiments.

Experimental Study and Theory Prediction on Adiabatic Shear Critical Conditions of Hardened AISI 1045 Steel

2011 ◽  
Vol 189-193 ◽  
pp. 3061-3065
Author(s):  
Guo He Li ◽  
Tie Li Qi ◽  
Yu Jun Cai ◽  
Hong Jun Wang
Keyword(s):  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Rake Angle ◽  
Adiabatic Shear ◽  
Cutting Conditions ◽  
Critical Conditions ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Cutting Experiments

Orthogonal cutting experiments of hardened AISI1045 steel(45HRC) are performed to investigate the influence of cutting conditions on adiabatic shear which occurs in the process of chip formation of many materials. It is found that the cutting speed, cutting depth and rake angle all have influence on adiabatic shear and there is a critical cutting speed at which the adiabatic shear appears. By metallurgical observation, the critical cutting speed under different cutting depths and rake angles are given. A model based on linear pertubation analysis is used to predict the adiabatic shear critical cutting conditions of hardened AISI 1045 steel. The comparison of prediction results and that of expriments shows that this prediction model is valid.

Prediction of Critical Cutting Conditions of Adiabatic Shear in Orthogonal High Speed Cutting Based on Linear Pertubation Analysis

2010 ◽  
Vol 455 ◽  
pp. 137-140 ◽  
Author(s):  
Guo He Li ◽  
Min Jie Wang ◽  
Yu Jun Cai
Keyword(s):  
High Speed ◽  
Adiabatic Shear ◽  
Cutting Conditions ◽  
Critical Conditions ◽  
Linear Perturbation ◽  
High Speed Cutting ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Basic Equations ◽  
1045 Steel

A model is presented for the prediction of critical cutting conditions of adiabatic shear in orthogonal high speed cutting. Considering the influence of compression stress, a critical criterion of adiabatic shear in orthogonal high speed cutting is given by linear perturbation on the compress-shear deformation continuum mechanics basic equations of the primary shear zone. Combining with the relationship of cutting conditions and deformation ones, also the materials constitutive realtionship, a pridiction model, which expressed by cutting conditions and materials properties is established. As an example, the adiabatic shear critical conditions of AISI 1045 steel are predicted, and cutting experiments are performed. The prediction results are consistent with that of experiments.

New Thermal Issues on the Modelling of Tool-Workpiece Interaction: Application to Dry Cutting of AISI 1045 Steel

2011 ◽  
Vol 223 ◽  
pp. 286-295 ◽  
Author(s):  
Cédric Courbon ◽  
Tarek Mabrouki ◽  
Joël Rech ◽  
Denis Mazuyer ◽  
Enrico D'Eramo
Keyword(s):  
Heat Flux ◽  
Hot Spot ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Contact Length ◽  
Dry Cutting ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Carbide

The present work proposes to enhance the thermal interface denition in Finite Element (FE) simulations of machining. A user subroutine has been developed in Abaqus/Explicit © to implement a new experimentally-based heat partition model extracted from tribological tests. A 2D Arbitrary-Lagragian-Eulerian (ALE) approach is employed to simulate dry orthogonal cutting of AISI 1045 steel with coated carbide inserts. Simulation results are compared to experimental ones over a whole range of cutting speeds and feed rates in terms of average cutting forces, chip thickness, tool chip contact length and heat flux. This study emphasizes that heat transfer and temperature distribution in the cutting tool are drastically in uenced by the thermal formulation used at the interface. Consistency of the numerical results such as heat flux transmitted to the tool, peak temperature as well as hot spot location can be denitively improved.

A Metallo-Thermomechanically Coupled Analysis of Orthogonal Cutting of AISI 1045 Steel

2012 ◽  
Vol 134 (5) ◽  
Author(s):  
Hongtao Ding ◽  
Yung C. Shin
Keyword(s):  
Experimental Data ◽  
Cutting Force ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Machining Process ◽  
Coupled Analysis ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Materials often behave in a complicated manner involving deeply coupled effects among stress/stain, temperature, and microstructure during a machining process. This paper is concerned with prediction of the phase change effect on orthogonal cutting of American Iron and Steel Institute (AISI) 1045 steel based on a true metallo-thermomechanical coupled analysis. A metallo-thermomechanical coupled material model is developed and a finite element model (FEM) is used to solve the evolution of phase constituents, cutting temperature, chip morphology, and cutting force simultaneously using abaqus. The model validity is assessed using the experimental data for orthogonal cutting of AISI 1045 steel under various conditions, with cutting speeds ranging from 198 to 879 m/min, feeds from 0.1 to 0.3 mm, and tool rake angles from −7 deg to 5 deg. A good agreement is achieved in chip formation, cutting force, and cutting temperature between the model predictions and the experimental data.

scholarly journals Effect of Cutting Conditions on the Residual Stresses Induced by Milling of AISI 1045 Steel

2019 ◽  
Vol 8 (2) ◽  
pp. 1462-1465 ◽  
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Diffraction Method ◽  
Cutting Conditions ◽  
Depth Of Cut ◽  
Machining Processes ◽  
Machined Surface ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

The nature of residual stresses caused by machining processes has been relevant to the study of component performance for decades. The concept that cutting parameters affect the magnitude and nature of residual stress is well known. In order to reduce the residual stresses on a machined surface, it is important to identify the extent of the effect of cutting conditions. This paper presents the effect of depth of cut and tool speed on milling induced residual stresses. Speed and depth of cut were varied when milling several AISI 1045 Steel specimens. Stresses were measured with the X-ray diffraction method and corroborated with mathematical modelling on an FEA software. A relationship between tool speed and residual stress, and depth of cut and residual stress was thus obtained.

Selection of Optimal Tool Geometry and Cutting Conditions in End Milling With Graphite as a Solid Lubricant

2004 ◽  
Author(s):  
N. Suresh Kumar Reddy ◽  
P. Venkateswara Rao
Keyword(s):  
Solid Lubricant ◽  
End Milling ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Tool Geometry ◽  
Cutting Fluids ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Coated Carbide

Coolants dissipate the heat generated during machining and hence improve productivity, machinability, etc. However, the use of cutting fluids in machining operations may seriously degrade the quality of environment. So, in recent years researchers have started machining with the use of solid lubricants with the aim of improving machining performance and overcome some of the limitations that arise with the use of cutting fluids or while machining dry. This paper deals with an investigation on using graphite as a solid lubricant to reduce the heat generated at the milling zone for improving the surface roughness of the machined AISI 1045 steel. An experimental setup has been developed to maintain constant flow rate of graphite powder continuously on to the workpiece and tool interface zone. The experimental studies have been conducted to see the effect of tool geometry (radial rake angle and nose radius) and cutting conditions (cutting speed and feed rate) on the machining response such as surface finish in solid lubricant assisted machining using four fluted solid TiAlN coated carbide cutters. Results indicate that there is a considerable improvement in the performance of milling AISI 1045 steel using graphite as a solid lubricant when compared with machining with cutting fluids. An attempt has also been made to select optimum tool geometry and cutting conditions in end milling with graphite as a solid lubricant by using the prediction model obtained from these experimental results.

Prelimenary Study on Thermomechanical Modelling of Cutting Process

2011 ◽  
Vol 383-390 ◽  
pp. 6741-6746
Author(s):  
Wan Masrurah Bt Hairudin ◽  
Mokhtar B. Awang
Keyword(s):  
Maximum Stress ◽  
Orthogonal Cutting ◽  
Cutting Process ◽  
Maximum Temperature ◽  
Arbitrary Lagrangian Eulerian ◽  
Element Analysis ◽  
Ale Formulation ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

In this paper, thermo mechanical modelling of cutting process has been developed using a commercially available finite element analysis software, ABAQUS. A 2-D orthogonal cutting has been modelled using Arbitrary Lagrangian-Eulerian (ALE) formulation. The Johnson-Cook plasticity model has been assumed to describe the material behaviour during the process. This study is aimed at temperature and stresses distributions during machining of AISI 1045 steel with different rake angles; α=0° and α= -10°. The results showed that the maximum stress for 0° and -10° are 963MPa and 967MPa while the maximum temperature results shown that 771°C and 347°C.

Predictive Analytical and Thermal Modeling of Orthogonal Cutting Process—Part II: Effect of Tool Flank Wear on Tool Forces, Stresses, and Temperature Distributions

2005 ◽  
Vol 128 (2) ◽  
pp. 445-453 ◽  
Author(s):  
Yiğit Karpat ◽  
Tuğrul Özel
Keyword(s):  
Flank Wear ◽  
Thermal Modeling ◽  
Orthogonal Cutting ◽  
Force Model ◽  
Stress Distributions ◽  
Tool Flank Wear ◽  
Temperature Distributions ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

In this paper, predictive modeling of cutting and ploughing forces, stress distributions on tool faces, and temperature distributions in the presence of tool flank wear are presented. The analytical and thermal modeling of orthogonal cutting that is introduced in Part I of the paper is extended for worn tool case in order to study the effect of flank wear on the predictions. Work material constitutive model based formulations of tool forces and stress distributions at tool rake and worn flank faces are utilized in calculating nonuniform heat intensities and heat partition ratios induced by shearing, tool-chip interface friction, and tool flank face-workpiece interface contacts. In order to model forces and stress distributions under the flank wear zone, a force model from Waldorf (1996) (“Shearing Ploughing, and Wear in Orthogonal Machining,” Ph.D. thesis, University of Illinois at Urbana-Champaign, IL) is adapted. Model is tested and validated for temperature and force predictions in machining of AISI 1045 steel and AL 6061-T6 aluminum.

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