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.

An Integral Method to Determine Workpiece Flow Stress and Friction Characteristics in Metal Cutting

2015 ◽  
Vol 9 (6) ◽  
pp. 775-781
Author(s):  
Norfariza Wahab ◽  
◽  
Yumi Inatsugu ◽  
Satoshi Kubota ◽  
Soo-Young Kim ◽  
...  
Keyword(s):  
Flow Stress ◽  
Strain Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Edge ◽  
Cutting Process ◽  
Machining Parameters ◽  
Friction Characteristics ◽  
High Speed Cutting

In recent times, numerical simulation techniques have been commonly used to estimate and predict machining parameters such as cutting forces, stresses, and temperature distribution. However, it is very difficult to estimate the flow stress of a workpiece and the friction characteristics at a tool/chip interface, particularly during a high-speed cutting process. The objective of this study is to improve the accuracy of the present method and simultaneously determine the characteristics of the flow stress of a workpiece and friction at the cutting edge under a high strain rate and temperature during the cutting process. In this study, the Johnson-Cook (JC) flow stress model is used as a function of strain, strain rate, and temperature. The friction characteristic was estimated by minimizing the difference between the predicted and measured results of principal force, thrust force, and shear angle. The shear friction equation was used to estimate the friction characteristics. Therefore, by comparing the measured values of the cutting forces with the predicted results from FEM simulations, an expression for workpiece flow stress and friction characteristics at the cutting edge during a high-speed cutting process was estimated.

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.

2D-FEM SIMULATION OF THE ORTHOGONAL HIGH SPEED CUTTING PROCESS

2001 ◽  
Vol 5 (3) ◽  
pp. 323-340 ◽  
Author(s):  
F. Klocke ◽  
H.-W. Raedt ◽  
S. Hoppe
Keyword(s):  
High Speed ◽  
Fem Simulation ◽  
Cutting Process ◽  
High Speed Cutting

Finite Element Analysis of Cutting Forces in High Speed Machining

2006 ◽  
Vol 532-533 ◽  
pp. 753-756 ◽  
Author(s):  
Jun Zhao ◽  
Xing Ai ◽  
Zuo Li Li
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Fem Simulation ◽  
Chip Thickness ◽  
Cutting Conditions ◽  
Cutting Process ◽  
Undeformed Chip Thickness ◽  
High Speed Cutting

The Finite Element Method (FEM) has proven to be an effective technique to investigate cutting process so as to improve cutting tool design and select optimum cutting conditions. The present work focuses on the FEM simulation of cutting forces in high speed cutting by using an orthogonal cutting model with variant undeformed chip thickness under plane-strain condition to mimic intermittent cutting process such as milling. High speed cutting of 45%C steel using uncoated carbide tools are simulated as the application of the proposed model. The updated Lagrangian formulation is adopted in the dynamic FEM simulation in which the normalized Cockroft and Latham damage criterion is used as the ductile fracture criterion. The simulation results of cutting force components under different cutting conditions show that both the thrust cutting force and the tangential cutting force increase with the increase in undeformed chip thickness or feed rate, whereas decrease with the increase in cutting speed. Some important aspects of modeling the high speed cutting are discussed as well to expect the future work in FEM simulation.

Observations on Orthogonal Cutting Processes - Effect of Friction between Tool and Work Material -

2008 ◽  
Vol 389-390 ◽  
pp. 169-174
Author(s):  
Junya Okida ◽  
Hideki Moriguchi ◽  
Takao Nishioka ◽  
Hiromi Yoshimura
Keyword(s):  
Alloy Steel ◽  
Tribological Properties ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Good Method ◽  
Video Camera ◽  
Cutting Process ◽  
Cutting Test ◽  
The Difference ◽  
Cutting Processes

In this paper, orthogonal cutting tests of alloy steel, aluminum alloy and Ti6Al4V have been carried out to consider the cutting mechanism from the viewpoint of friction between the tool and workpiece. The cutting processes were observed in detail using a high-speed video camera. The cutting process of alloy steel was greatly affected by its tribological properties compared with those of the other two work materials. In the cutting process of alloy steel, there were three stages in relation to the state of the tool rake face and temperature. The difference between non coated and coated tools was marked in the later stages. From the discussion on the experimental results, it is considered that the thrust force is suitable for representing the tribological properties between the tool and workpiece. It is concluded that the orthogonal cutting test is a good method for evaluating tribological properties between the tool and workpiece.

The Forming Mechanism of Surface Defects on Machined Surface in High-Speed Cutting of SiCp/Al Composites

2013 ◽  
Vol 579-580 ◽  
pp. 171-176
Author(s):  
Yang Jun Wang ◽  
Ming Qiang Pan ◽  
Tao Chen ◽  
Li Guo Chen
Keyword(s):  
High Speed ◽  
Surface Defects ◽  
Fem Simulation ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Machined Surface ◽  
High Speed Cutting ◽  
Forming Mechanism ◽  
Simulation And Experiment ◽  
Method Model

For investigating the machined surface defects in high-speed cutting of SiCp/Al composites. The simulation and experiment of high-speed cutting process is done. The simulation of high-speed cutting process using the Cowper-Symonds model is established to explore the forming mechanism of the machined surface defects. The results show that the machined surface defects include small pit, big pit, groove and the raised particle. The experiment which uses the same cutting parameters with the simulation of FEM (Finite Element Method) model is carried out to verify the results of FEM simulation. The results indicate that the forming mechanism of machined surface defects prove to be true.

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.

Flow characteristics and constitutive equations of flow stress in high speed cutting Alloy 718

2017 ◽  
Vol 728 ◽  
pp. 854-862 ◽  
Author(s):  
ZhaoPeng Hao ◽  
FangFang Ji ◽  
YiHang Fan ◽  
JieQiong Lin ◽  
XiaoYong Liu ◽  
...  
Keyword(s):  
Flow Stress ◽  
Constitutive Equations ◽  
High Speed ◽  
Flow Characteristics ◽  
Alloy 718 ◽  
High Speed Cutting

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.

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