Contact and friction analysis at tool-chip interface to high-speed machining

Brocail, Julien; Watremez, Michel; Dubar, Laurent; Bourouga, Brahim

doi:10.1007/s12289-008-0128-7

Cited by 8 publications

(4 citation statements)

References 18 publications

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“…The study carried out by Brocail et Al [2,12,13] is led with AISI 1045 steel and an uncoated carbide tool. An experimental device has been first designed to simulate the friction behavior at the tool-chip interface only in the zone near the cutting edge.…”

Section: Figure 1 Advanced Law Proposed By Ben Abdelalimentioning

confidence: 99%

Implementation of Advanced Frictional Laws for Modelling of High Speed Machining

Senecaut

Watremez

Méresse

et al. 2013

KEM

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High-speed machining is submitted to economical and ecological constraints. Optimization of cutting processes must increase productivity, reduce tool wear and control residual stresses in the workpiece. Developments of numerical approaches to simulate accurately high-speed machining process are therefore necessary since in situ optimization is long and costly. To get this purpose, rheological behaviour of both antagonists and representative friction models at tool-chip interface has to be studied as encountered during high-speed machining process. The study is led with AISI 1045 steel and an uncoated carbide tool. An experimental device has been first designed to simulate the friction behaviour at the tool-chip interface only in the zone near the cutting edge. Several tests are then performed to provide experimental data and these data are used to define the friction coefficient versus to the contact pressure, the sliding velocity and the interfacial temperature by a new formulation frictional law given by Brocail et al (2010). A two-dimensional finite element model of orthogonal cutting is developed with Abaqus/explicit software. An Arbitrary Lagrangian-Eulerian (ALE) formulation is used to predict chip formation, temperature, chip-tool contact length, chip thickness, and cutting forces. This numerical model of orthogonal cutting is then validated by comparing these process variables to experimental and numerical results obtained by Filice et al. (2006). This model makes possible qualitative analysis of input parameters related to cutting process and frictional models. A sensitivity analysis has been performed on the main input parameters (coefficients of the Johnson-Cook law, contact and thermal parameters) with the finite element model. The interfacial law determined by Brocail et al (2010) is implemented on this finite element model of machining and leads to improve numerical approaches of machining. Nevertheless, even if this law enables to reduce results between experimental and numerical approaches, some differences are still substantial. The advanced friction law must be complemented for higher sliding velocities and this work using a new specific experimental device will be presented in the second part of this paper.

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Section: Figure 1 Advanced Law Proposed By Ben Abdelalimentioning

confidence: 99%

Implementation of Advanced Frictional Laws for Modelling of High Speed Machining

Senecaut

Watremez

Méresse

et al. 2013

KEM

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“…An optimisation on production line would be timeconsuming. Thus, numerical approaches emerged to simulate accurately high speed machining processes [1,2].…”

Section: Introductionmentioning

confidence: 99%

Evolution of Dynamic Recrystallization of AISI-1045 Steel under Critical Friction Conditions

Mercier¹,

Watremez²,

Brocail

et al. 2014

AMR

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To determine the impact of dynamic recrystallization on frictional behaviour in the tool-chip interface, a specific friction test called the Warm and Hot Upsetting Sliding Test (WHUST) is implemented. This friction bench simulates tests with contact pressure, sliding velocity, contactor and specimen temperatures similar to industrial ones. Several tests are performed on specimens at different sliding speed, penetrations and work-piece temperatures to reach different dynamically recrystallized states. A numerical model of this test using Arbitrary Lagrangian Eulerian (ALE) method is implemented. Thanks to a specific rheological model, we are able to predict the evolution of the volume fraction of recrystallized grains.

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“…Contact pressure and temperature value of about 750 MPa and 950 °C, respectively, can be reached with the test proposed by Meiller et al (2000). Friction devices, recently designed by Bonnet et al (2008) and by Brocail et al (2008), can reach relevant contact conditions in pressure and temperature. Very recent works led by Rech et al (2009) suggest a friction model depending on the average sliding velocity.…”

Section: Introductionmentioning

confidence: 99%

“…Very recent works led by Rech et al (2009) suggest a friction model depending on the average sliding velocity. Brocail et al (2008) have also proposed a new frictional model depending on sliding velocity and interfacial pressure and temperature. These both authors agree that using a coulomb model with constant friction coefficient is unsuitable to simulate friction phenomena at the tool-chip interface.…”

Section: Introductionmentioning

confidence: 99%

Finite element modelling of orthogonal cutting: sensitivity analysis of material and contact parameters

Watremez

Méresse

Dubar

et al. 2012

IJSPM

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Brocail. Finite element modelling of orthogonal cutting: sensitivity analysis of material and contact parameters. Abstract This paper presents a two-dimensional finite element model of orthogonal cutting. The proposed model is developed with Abaqus/explicit software. An Arbitrary Lagrangian-Eulerian (ALE) formulation is used to predict chip formation, temperature, chip-tool contact length, chip thickness, and cutting forces. This numerical model of orthogonal cutting is then validated by comparing these process variables to experimental and numerical results obtained by Filice et al. (2006). This model makes possible qualitative analysis of input parameters related to cutting process and frictional models. A sensitivity analysis is performed on the main input parameters (coefficients of the Johnson-Cook law, contact and thermal parameters) with the finite element model. This analysis allows the identification of significant parameters and their tolerance limitsidentification. This study draws to input parameters which have to be determined accurately as far as possible in order to improve numerical approaches of machining.

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Contact and friction analysis at tool-chip interface to high-speed machining

Cited by 8 publications

References 18 publications

Implementation of Advanced Frictional Laws for Modelling of High Speed Machining

Implementation of Advanced Frictional Laws for Modelling of High Speed Machining

Evolution of Dynamic Recrystallization of AISI-1045 Steel under Critical Friction Conditions

Finite element modelling of orthogonal cutting: sensitivity analysis of material and contact parameters

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