Arbitrary Lagrangian Eulerian analysis on cutting with a honed tool

Kishawy, Hossam A.; Deiab, Ibrahim; Haglund, A.J.

doi:10.1243/09544054jem931

Cited by 9 publications

(3 citation statements)

References 11 publications

(24 reference statements)

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“…However, the workpiece material that flows towards the cutting edge is forced to split into two parts, one forming the chip and the other forming the new surface on the workpiece material. The location of the stagnation point, which has been reported to have an important role not least on the plastic strains in the newly created surface (Nasr et al 2007, Kishawy et al 2008, was found to move upwards with increasing cut-off value. This counteracted the increase in feed force resulting from increased friction.…”

Section: Cutting Forcesmentioning

confidence: 80%

“…Umbrello et al (2007) and Umbrello (2008) performed a sensitivity study to investigate how the constants used in the J-C material model for AISI 316L and Ti6Al4V alloys influence simulated cutting forces, temperature, chip morphology and in the former case the residual stresses. Kishawy et al (2008) studied the influence of edge radius in orthogonal cutting of AISI 4140 by evaluating the cutting forces, chip thickness, temperature and stagnation point using an FE model in which a J-C material model was used. A J-C material model was also used by Woon et al (2008) to study the effect of edge radius on contact phenomena in micro-cutting of AISI 1045.…”

Section: Literature Reviewmentioning

confidence: 99%

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Modelling high strain rate phenomena in metal cutting simulation

Wedberg

Svoboda

Lindgren

2012

Modelling Simul. Mater. Sci. Eng.

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Chip formation in metal cutting is associated with large strains and high strain rates, concentrated locally to deformation zones in front of the tool and beneath the cutting edge. Furthermore, dissipative plastic work and friction work generate high local temperatures. These phenomena together with numerical complications make modelling of metal cutting difficult. Material models, which are crucial in metal cutting simulations, are usually calibrated based on data from material testing. Nevertheless, the magnitude of strains and strain rates involved in metal cutting are several orders higher than those generated from conventional material testing. A highly desirable feature is therefore a material model that can be extrapolated outside the calibration range. In this study, two variants of a flow stress model based on dislocation density and vacancy concentration are used to simulate orthogonal metal cutting of AISI 316L stainless steel. It is found that the addition of phonon drag improves the results somewhat but the addition of this phenomenon still does not make it possible to extrapolate the constitutive model reliably outside its calibration range.

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Section: Cutting Forcesmentioning

confidence: 80%

Section: Literature Reviewmentioning

confidence: 99%

Modelling high strain rate phenomena in metal cutting simulation

Wedberg

Svoboda

Lindgren

2012

Modelling Simul. Mater. Sci. Eng.

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“…In order to eliminate these problems, some authors have developed a new Arbitrary Lagrangian-Eulerian formulation which enables the mesh to deform freely on its free boundaries (Lagrangian part) and the material to flow without distortion through the mesh (Eulerian part). 9–18 After a phase of mesh adaptation, especially the chip, the ALE makes it possible to simulate a stabilized cutting situation. Unfortunately, the mesh stabilization phase very often leads to calculation errors due to mesh distortion at the beginning of the simulation.…”

Section: Introductionmentioning

confidence: 99%

Comparison of the CEL and ALE approaches for the simulation of orthogonal cutting of 15-5PH and 42CrMo4 materials

Aridhi

Perard

Valiorgue

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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The modeling of cutting processes by the finite element method represents a great challenge for scientific researchers. Indeed, the plastic strain and strain rate in cutting induce a high risk of mesh distortion, especially for models based on a Lagrangian formulation which were the first to be developed. To overcome this problem other formulations, such as the Arbitrary Eulerian-Lagrangian (ALE), which is a combination of the classical formulations (Eulerian and Lagrangian), have been developed. Despite very interesting results in the simulation of orthogonal cutting, the implementation of this type of model remains delicate, and in particular the choice of initial geometrical conditions which can lead to a sudden stop of the calculation induced by a mesh distortion. To overcome these limitations, the Coupled Eulerian-Lagrangian (CEL) approach has been developed to simulate the orthogonal cutting process. In this paper, the CEL and ALE approaches were compared to simulate the orthogonal cutting process. The first objective was to compare the quality of the predicted physical quantities (forces, chips) over a wide range of cutting speeds and cutting thicknesses for two different materials. The second objective was to evaluate the time required for a complete simulation, integrating the time to set up the initial conditions (chip geometry) and finally the computation time of the machining operation. This work has shown that ALE and CEL formulations lead to very similar quantitative results that are pretty close to the experimental results. The ALE formulation has the advantage of having a reduced computation time compared to the CEL formulation. However, the preparation of the simulation is easy and robust for the CEL, whereas the selection of initial geometrical conditions for the ALE calculation requires several trials and errors before finding stable conditions. The CEL formulation is therefore a solution to be favored when launching several simulations in an automated way thanks to its reliability.

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