Determination of work material flow stress and friction for FEA of machining using orthogonal cutting tests

Özel, Tuğrul; Zeren, Erol

doi:10.1016/j.jmatprotec.2004.04.162

Cited by 146 publications

(75 citation statements)

References 12 publications

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“…Like for Coulomb parameter, it is possible to obtain a data file which gives the good forces values. During our work, we have found four sets of different Johnson-Cook parameters in the literature for the Ti6Al4V alloy [24][25][26][27]. These data are reproduced in Table 3.…”

mentioning

confidence: 88%

Toward a better understanding of tool wear effect through a comparison between experiments and SPH numerical modelling of machining hard materials

Calamaz

Limido

Nouari

et al. 2009

International Journal of Refractory Metals and Hard Materials

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is an open access repository that collects the work of Arts et Métiers ParisTech researchers and makes it freely available over the web where possible. The aim of this study is to improve the general understanding of tungsten carbide (WC-Co) tool wear under dry machining of the hard-to-cut titanium alloy Ti6Al4V. The chosen approach includes experimental and numerical tests. The experimental part is designed to identify wear mechanisms using cutting force measurements, scanning electron microscope observations and optical profilometer analysis. Machining tests were conducted in the orthogonal cutting framework and showed a strong evolution of the cutting forces and the chip profiles with tool wear. Then, a numerical method has been used in order to model the machining process with both new and worn tools. The use of smoothed particle hydrodynamics model (SPH model) as a numerical tool for a better understanding of the chip formation with worn tools is a key aspect of this work. The predicted chip morphology and the cutting force evolution with respect to the tool wear are qualitatively compared with experimental trends. The chip formation mechanisms during dry cutting process are shown to be quite dependent from the worn tool geometry. These mechanisms explain the high variation of the experimental and numerical feed force between new and worn tools.

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mentioning

confidence: 88%

Toward a better understanding of tool wear effect through a comparison between experiments and SPH numerical modelling of machining hard materials

Calamaz

Limido

Nouari

et al. 2009

International Journal of Refractory Metals and Hard Materials

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“…Many material constants can be found in literature for the Ti-6Al-4V alloy [14,[34][35][36][37][38]. Fig.…”

Section: Cutting and Feed Forcesmentioning

confidence: 99%

A new material model for 2D numerical simulation of serrated chip formation when machining titanium alloy Ti–6Al–4V

Calamaz

Coupard

Girot

2008

International Journal of Machine Tools and Manufacture

547

314

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is an open access repository that collects the work of Arts et Métiers ParisTech researchers and makes it freely available over the web where possible. AbstractA new material constitutive law is implemented in a 2D finite element model to analyse the chip formation and shear localisation when machining titanium alloys. The numerical simulations use a commercial finite element software (FORGE 2005 s ) able to solve complex thermo-mechanical problems. One of the main machining characteristics of titanium alloys is to produce segmented chips for a wide range of cutting speeds and feeds. The present study assumes that the chip segmentation is only induced by adiabatic shear banding, without material failure in the primary shear zone. The new developed model takes into account the influence of strain, strain rate and temperature on the flow stress and also introduces a strain softening effect. The tool chip friction is managed by a combined Coulomb-Tresca friction law. The influence of two different strain softening levels and machining parameters on the cutting forces and chip morphology has been studied. Chip morphology, cutting and feed forces predicted by numerical simulations are compared with experimental results.

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“…The workpiece is modelled as a deformable body with rigid-plastic material data which is dependent on strain, strain rate and temperature. The flow stress is a function of strain, strain rate and temperature [18][19][20]:…”

Section: Finite Element Modeling Of Rectangular Groove Cuttingmentioning

confidence: 99%

Numerical Analysis of Rectangular Groove Cutting with Different RC Tools

Deng¹,

Li²,

Zi³

et al. 2013

Int. j. simul. model.

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The paper reports an advanced finite element analysis code for the investigation of the cutting process of rectangular groove. Three different restricted contact tools (RC tools) with rectangular, trapezoidal and double-trapezoidal shapes were employed in this study. The cutting force, feed force and rake face temperature distribution during the cutting process were analysed. The simulation results show that asymmetric tool-chip restricted contact shape causes the chip to break more easily than the symmetric tools. The RC tool shows significant reductions both in cutting force (6~8 %) and feed force (70~80 %) than traditional tools. It is also found that the RC tools give 12 % reduction in mean temperature on tool rake face compared to those of traditional tools. The simulation results indicate that the tools with asymmetric tool-chip contact shapes have advantages over symmetrical ones in terms of decreasing chip breakage, reducing cutting force and tool cooling.

show abstract

Determination of work material flow stress and friction for FEA of machining using orthogonal cutting tests

Cited by 146 publications

References 12 publications

Toward a better understanding of tool wear effect through a comparison between experiments and SPH numerical modelling of machining hard materials

Toward a better understanding of tool wear effect through a comparison between experiments and SPH numerical modelling of machining hard materials

A new material model for 2D numerical simulation of serrated chip formation when machining titanium alloy Ti–6Al–4V

Numerical Analysis of Rectangular Groove Cutting with Different RC Tools

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