A novel hybrid predictive model and validation of unique hook-shaped residual stress profiles in hard turning

Guo, Y. B.; Anurag, S.; Jawahir, I.S.

doi:10.1016/j.cirp.2009.03.110

Cited by 42 publications

(8 citation statements)

References 10 publications

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“…It is worthy of notice that not all the cutting power is done to the machined surface. The work done by F Cx and F Cy are mostly on the chip and is taken away continuously during machining process; however, due to the rounded cutting edge, part of the material in front of the cutting edge may flow downwards and become part of the machined surface, and a separation point exists ahead of the stagnation zone [26][27][28], as shown in Fig. 2.…”

Section: Theoretical Analysis 21 Effective Cutting Power In Face Milmentioning

confidence: 99%

Energy criteria for machining-induced residual stresses in face milling and their relation with cutting power

Feng

Zhang

et al. 2015

Int J Adv Manuf Technol

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Machining-induced residual stresses can significantly influence the performance of machined parts, and many scholars have contributed efforts to measure, evaluate, predict, and control the distribution of residual stresses. In most published researches, the residual stresses are analyzed as the function of cutting parameters, tool parameters, or material properties, but any of these parameters cannot decide the distribution of residual stresses solo and directly. And the commonly used evaluation criteria, like surface value, peak value, and existing range, cannot reflect the overall distribution of residual stresses. In this paper, a new approach to study this issue was proposed, and the cutting loads, the cutting parameters, and the evaluation of residual stress field were unified to the concept of energy and its mutual transformation with mechanical work. The effective cutting power on the machined surface was analyzed, and the integral of strain energy density over depth and the power of stored strain energy were supposed to be the energy criteria of residual stress field. Face milling experiments were carried out, and the cutting forces and the in-depth residual stress distribution were measured. According to the methodology proposed, the results showed that with the increase of effective cutting power, the power of stored strain energy increases with growing rate, which means that the partition of cutting work stored as strain energy increases simultaneously. And the integral of strain energy density over depth grows linearly with the effective cutting power under the experimental conditions in this study.

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Section: Theoretical Analysis 21 Effective Cutting Power In Face Milmentioning

confidence: 99%

Energy criteria for machining-induced residual stresses in face milling and their relation with cutting power

Feng

Zhang

et al. 2015

Int J Adv Manuf Technol

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“…Following the established hybrid FEA simulation approach [9] as shown in Fig. 1, plane strain element type CPE4RT of 4-node and reduced integration elements with temperature degree of freedom were used to mesh the workpiece as shown in Fig.…”

Section: Mesh and Simulation Conditionsmentioning

confidence: 99%

Predictive model to decouple the contributions of friction and plastic deformation to machined surface temperatures and residual stress patterns in finish dry cutting

Anurag

Guo

2010

Front. Mech. Eng. China

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Temperature on the machined surface is critical for surface integrity and the performance of a precision component. However, the temperature of a machined surface is challenging for in-situ measurement. Furthermore, the individual contribution of tool/work friction and plastic deformation of work materials to surface temperature is very difficult to quantify because the measured temperature is always the resultant temperature. This lack of understanding on the temperature distribution blocks the design of effective cutting tool geometries and materials to minimize surface temperature. This study provides a finite element method based on a predictive model to decouple the contributions of tool/work friction and material plastic deformation to surface temperature in a dry cutting process. The study shows that the plastic deformation of work material contributes to the majority of surface temperature, whereas the tool/work friction contribution is secondary. High temperatures are produced when more materials are plowed under the cutting edge. A large tool/ work friction leads to higher surface temperatures, and the use of a cutting tool with physical properties in process simulation significantly improves the accuracy of predicted surface temperatures. Residual stress reversal from subsurface maximum residual to surface maximum residual stress may occur when tool/work friction increases.

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“…Davim and Maranhão 5 studied the plastic strain and plastic strain rate in high-speed machining of steel AISI 1045 using AdvantEdge ™ , supplied by Third Wave Systems. Guo et al 6,7 proposed a new coupled thermal–mechanical hybrid model via the user material subroutine using Abaqus/Explicit.…”

Section: Introductionmentioning

confidence: 99%

Three-dimensional finite element modeling of high-speed end milling operations of Ti-6Al-4V

Wang

Zhao

et al. 2013

Proceedings of the Institution of Mechanical Engineers, Part B:

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This article presents the development of a three-dimensional finite element model to simulate the high-speed end milling of Ti-6Al-4V titanium alloy based on the commercial finite element package Abaqus/Explicit. The Johnson–Cook material constitutive model was employed to model the flow stress behavior of the workpiece. Zorev’s friction model was used to determine the frictional behavior of the tool–chip interface, and Johnson–Cook shear failure criterion was used to realize chip separation. Based on the three-dimensional finite element model, cutting forces in three directions were predicted under different cutting conditions, and chip evolution and morphologies of different cutting parameters were also analyzed. Corresponding high-speed end milling tests were conducted, and cutting forces were measured using a piezoelectric dynamometer in order to validate the finite element model. The simulation results demonstrate an acceptable agreement with experimental results in both the chip morphologies and cutting forces in the range of cutting speed and feed rates considered.

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A novel hybrid predictive model and validation of unique hook-shaped residual stress profiles in hard turning

Cited by 42 publications

References 10 publications

Energy criteria for machining-induced residual stresses in face milling and their relation with cutting power

Energy criteria for machining-induced residual stresses in face milling and their relation with cutting power

Predictive model to decouple the contributions of friction and plastic deformation to machined surface temperatures and residual stress patterns in finish dry cutting

Three-dimensional finite element modeling of high-speed end milling operations of Ti-6Al-4V

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