No abstract

The constitutive equation of mechanics, namely the stress–strain model of the material, is used to describe the mathematical expression of the mechanical properties of the material (stress–strain–intensity–time relationship). In the cutting simulation of metals, the material constitutive model needs to be established. To study the cutting mechanism of gray cast iron using the finite element method (FEM), a series of split Hopkinson press bar (SHPB) tests are carried out to achieve the stress–strain curves of gray cast iron under different strain rates and temperatures. In the cutting simulation of gray cast iron, the Johnson–Cook (JC) constitutive equation is used to reflect the mechanical behavior during the cutting process. The calculation of JC constants is analyzed deeply and obtained from the SHPB test data. One orthogonal finite element model is developed with the JC material model to reveal the cutting mechanism of gray cast iron. The chip formation, stress distribution, temperature distribution, and cutting force are investigated through the cutting simulation. At the same time, cutting experiments of gray cast iron are carried out for validating the simulation results. The results of the cutting simulation and experiments show a good agreement.

Grinding is used to reduce form error and improve the surface quality of workpiece in metal cutting. To investigate the grinding process of cast iron, a series of grinding tests and simulation of cast iron were carried out. At the same time, the finite element method was used to establish a finite element model to simulate the grinding process of cast iron. In the model, the dynamic effects, thermo-mechanical coupling, Johnson–Cook constitutive model, material damage model, and contact model were taken into account. Then, the grinding process of cast iron was simulated using the established finite element model in the ABAQUS software. Material remove, residual stress, grinding force, and cutting temperature were achieved through the simulation. In addition, the effect of the main grinding parameters (depth of grinding and spindle speed) on residual stress, grinding force, and surface quality in the grinding of cast iron was investigated.