Numerical Simulation of Orthogonal Cutting Process of a Kind of Difficult-to-Cut Material

2006 ◽  
Vol 532-533 ◽  
pp. 925-928 ◽  
Author(s):  
Jing Sheng ◽  
Wei Zheng Yuan
Keyword(s):  
Orthogonal Cutting ◽  
Simulated Data ◽  
Element Model ◽  
Parametric Modeling ◽  
Constitutive Law ◽  
Cutting Process ◽  
Initial State ◽  
Workpiece Material ◽  
Mechanical Coupling ◽  
Chip Separation

A orthogonal cutting of a kind of difficult-to-cut material is simulated using a finite element model, which is considered dynamic effects, thermo-mechanical coupling, tool-chip friction, chip separation criteria. Marc program is the computational tool in the model. Johnson-Cook’s model is employed as the constitutive law for the workpiece material. The frictional behavior of the sticking and sliding tool-chip interface is described by Coulomb’s law. Remeshing technique and mesh adaptive technique are also used. The research mainly specializes plane strain and continuous flow chip. The emphasis is placed on the parametric modeling of tool and workpiece. Then the cutting force and temperature in cutting process from initial state to steady state is conducted by simulation. Finally the Experimental value is compared with the simulated data.

Effect of Tool Flank Wear on the Orthogonal Cutting Process

2007 ◽  
Vol 329 ◽  
pp. 705-710 ◽  
Author(s):  
X.L. Zhao ◽  
Yong Tang ◽  
Wen Jun Deng ◽  
F.Y. Zhang
Keyword(s):  
Cutting Forces ◽  
Cutting Tool ◽  
Flank Wear ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Element Model ◽  
Cutting Process ◽  
Temperature Fields ◽  
Tool Flank Wear ◽  
Chip Separation

A coupled thermoelastic-plastic plane-strain finite element model is developed to study orthogonal cutting process with and without flank wear. The cutting process is simulated from the initial to the steady-state of cutting force and cutting temperature, by incrementally advancing the cutting tool forward. Automatic continuous remeshing is employed to achieve chip separation at the tool tip regime. The effect of the degree of the flank wear on the cutting forces and temperature fields is analyzed. With the flank wear increasing, the maximum cutting temperature values on the workpiece and cutting tool increase rapidly and the distribution of temperature changes greatly. The increase of tool flank wear produced slight increase in cutting forces but significant increase in thrust forces.

Effects of Tool Geometrical Parameters on the Chip Formation and Cutting Force in Orthogonal Cutting

2004 ◽  
Vol 471-472 ◽  
pp. 16-20 ◽  
Author(s):  
Gang Fang ◽  
P. Zeng
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Coupling Effect ◽  
Orthogonal Cutting ◽  
Rake Angle ◽  
Cutting Process ◽  
Geometrical Parameters ◽  
Actual Process ◽  
Mechanical Coupling ◽  
Chip Separation

The tool plays an important role in cutting process. The aim of this paper is to investigate the effect of tool geometrical parameters on the chip formation and cutting force with orthogonal cutting models. The large deformation Rigid-visco-plastic FEM program DEFORM-2DTM is used, and thermo-mechanical coupling effect are considered. The chip separation from workpiece is implemented by remeshing. Contrary to traditional cutting simulation, the workpiece is moved and the tool is fixed, which is consistent with actual process. The effects of tool rake angle on the chip geometry and cutting force are analyzed. The simulated cutting forces are compared with results in other references. The research results are a help to cutting process study and cutting tool design.

Identification of Process Damping Coefficient Based on Material Constitutive Property

2014 ◽  
Author(s):  
Xiaoliang Jin
Keyword(s):  
Energy Dissipation ◽  
Flank Wear ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Machining Process ◽  
Damping Coefficient ◽  
Chatter Stability ◽  
Workpiece Material ◽  
Process Damping ◽  
Constitutive Property

The contact between the tool flank wear land and wavy surface of workpiece causes energy dissipation which influences the tool vibration and chatter stability during a dynamic machining process. The process damping coefficient is affected by cutting conditions and constitutive property of workpiece material. This paper presents a finite element model of dynamic orthogonal cutting process with tool round edge and flank wear land. The process damping coefficient is identified based on the energy dissipation principle. The simulated results are experimentally validated.

Temperature Field Numerical Analysis of Machining Process Based on the Finite Element Analysis

2014 ◽  
Vol 621 ◽  
pp. 611-616 ◽  
Author(s):  
Yan Juan Hu ◽  
Yao Wang ◽  
Zhan Li Wang
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Element Model ◽  
Machining Process ◽  
Element Analysis ◽  
Mechanical Coupling

In order to study the temperature field distribution in the process of machining, the finite element theory was used to establish the orthogonal cutting finite element model, and the key technologies were discussed simultaneously. By using ABAQUS software for cutting AISI1045 steel temperature field of numerical simulation, the conclusion about changing rule of cutting temperature field can be gotten. The results show that this method can efficiently simulate the distribution of temperature field of the workpiece, cutter and scraps, which is effected by thermo-mechanical coupling in metal work process. It provides the theory evidence for the intensive study of metal-cutting principle, optimizing cutting parameters and improving processing technic and so on.

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.

scholarly journals Dynamic Recrystallization Observed at the Tool/Chip Interface in Machining

2015 ◽  
Vol 651-653 ◽  
pp. 1223-1228
Author(s):  
Yannick Senecaut ◽  
Michel Watremez ◽  
Julien Brocail ◽  
Laurence Fouilland-Paillé ◽  
Laurent Dubar
Keyword(s):  
Finite Element ◽  
Dynamic Recrystallization ◽  
Finite Element Model ◽  
Rheological Behavior ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Numerical Results ◽  
Constitutive Law ◽  
Rheological Models

In numerical approaches for high speed machining, the rheological behavior of machined materials is usually described by a Johnson Cook law. However, studies have shown that dynamic recrystallization phenomena appear during machining in the tool/chip interface. The Johnson Cook constitutive law does not include such phenomena. Thus, specific rheological models based on metallurgy are introduced to consider these dynamic recrystallization phenomena. Two empirical models proposed by Kim et al. (2003) and Lurdos (2008) are investigated in machining modeling. A two-dimensional finite element model of orthogonal cutting, using an Arbitrary Lagrangian-Eulerian (ALE) formulation, is developed with the Abaqus/explicit software. Specific rheological models are implemented in the calculation code thanks to a subroutine. This finite element model can then predict chip formation, interfacial temperatures, chip-tool contact length, cutting forces and chip thickness with also and especially the recrystallized area. New specific experiments on an orthogonal cutting test bench are conducted on AISI 1045 steel specimens with an uncoated carbide tool. Many tests are performed and results are focused on total chip thicknesses and recrystallized chip thicknesses. Finally, compared to numerical results got with a Johnson Cook law, numerical results obtained using specific rheological models to take into account dynamic recrystallization phenomena are very close to experimental results. This work shows also the influence of rheological behavior laws on predicted results in the modeling of high speed modeling.

A Fractal Analysis of Cutting Force in Simulation and Experiment

2013 ◽  
Vol 589-590 ◽  
pp. 122-127 ◽  
Author(s):  
Guang Ming Zheng ◽  
Jun Zhao ◽  
Xin Yu Song ◽  
Xiang Cheng
Keyword(s):  
Fractal Dimension ◽  
Cutting Force ◽  
Fractal Analysis ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Element Model ◽  
Cutting Process ◽  
Depth Of Cut ◽  
Practical Implementation ◽  
Mechanical Coupling

A 3D finite element model (FEM) of metal cutting was constructed based on the thermal-mechanical coupling theory. The cutting process of Sialon ceramic tools turning Inconel 718 was simulated and experimented. The effect of cutting speed, feed rate and depth of cut on the cutting force was analyzed. According to the correlation characteristics between the data points, the fractal characteristics of cutting forces in the cutting process were also investigated. The results showed that the cutting speed had a great effect on the fractal dimension of cutting force. The simulation results were in good agreement with the experimental findings. It was concluded that the minimum fractal dimension of cutting force was obtained at v=230 m/min under these experiment conditions. The fractal analysis is a simple and powerful tool for quantifying the stability of cutting process. The finding of this research is valuable for future practical implementation.

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.

Thermal-Mechanical Responses of Ti-6Al-4V during Orthogonal Cutting Process

2008 ◽  
Vol 273-276 ◽  
pp. 673-678 ◽  
Author(s):  
Mohd Nasir Tamin ◽  
Sudin Izman ◽  
Thet Thet Mon
Keyword(s):  
Shear Band ◽  
Diamond Tool ◽  
Orthogonal Cutting ◽  
Cvd Diamond ◽  
Cutting Edge ◽  
Cutting Process ◽  
Cutting Condition ◽  
Workpiece Material ◽  
Stick Slip ◽  
Mechanical Responses

Orthogonal metal cutting process involves large plastic deformation accompanied by excessive heat generation. This work addresses the thermal-mechanical responses of the workpiece material at the tool-workpiece contact. In this respect, the orthogonal cutting process of Ti-6Al-4V using CVD diamond tool is simulated using finite element method. The cutting condition consists of cutting speed, V=180 m/min, feed rate, t=0.125 mm/rev and width of cut of 1.25 mm. Eulerian formulation with coupled thermal-mechanical analysis is employed in the model. The Johnson- Cook constitutive equation is employed for Ti-6Al-4V workpiece material to accurately simulate the formation of shear bands. The stick-slip friction condition is modeled at the tool-chip interface. The sliding coefficient of friction of 0.8 and the limiting shear stress of 700 MPa for stick-slip condition are determined experimentally. Results show that high temperature and temperature gradient concentrate in the primary shear zone and the contact area between the tool rake face and the chip. A primary shear band is predicted in the workpiece ahead of the tool-workpiece contact face while the secondary shear band is formed in the chip. This highly-deformed shear band is revealed in the microstructure of etched chips. The predicted high strain rate results in build-up edge at tool cutting edge-chip contact. Low cutting condition of V=150 m/min, t=0.125 mm/rev promotes stagnant zone formation that helps preserve the cutting edge of the tool. The maximum predicted temperature at the cutting edge is in excess of 700 °C. Such high temperature level facilitates diffusion of carbon elements into the chips and conversely, elements of titanium into the CVD diamond tool.

Finite Element Simulation of the Orthogonal Cutting Based on Abaqus

2013 ◽  
Vol 821-822 ◽  
pp. 1410-1413 ◽  
Author(s):  
Xue Bin Liu ◽  
Xi Bin Wang ◽  
Chong Ning Li ◽  
San Peng Deng
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Friction Model ◽  
Cutting Process ◽  
Work Piece ◽  
Conduction Model ◽  
Element Analysis ◽  
Element Simulation

In view of orthogonal cutting, finite element simulation geometry is built. the friction model, thermal conduction model and chip separation model are established between chip and tool using Abaqus which is a finite element analysis software. Through a specific example, two-dimensional finite element model have been established, simulating the cutting process stress distribution of the work piece surface is also obtained during processing. While simulation analyzes the relationship between the rake angle and shear angle, the results of simulation and experiment are basically the same, thus further verify the credibility of Abaqus simulation results on orthogonal cutting, and the feasible is also proved of obtaining cutting data by the use of Abaqus simulation cutting process.

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