Finite element modeling and three-dimensional simulation of the turning process incorporating the material hardness

Biermann, Dirk; Höhne, Franziska; Sieben, Benedikt; Zabel, Andreas

doi:10.1007/s12289-010-0806-0

Cited by 9 publications

(4 citation statements)

References 4 publications

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“…In this context, the cutting speed v c , the feed rate f as well as the depth of cut a p represent appropriate machining parameters to be variegated for the purpose of validating a turning process simulation model [7]. The used cutting tools exhibit the specification CNMA 120408 and are composed of carbide metal base plates as well as soldered polycrystalline cubic boron nitride inserts.…”

Section: Methodsmentioning

confidence: 99%

A Novel Finite Element Approach to Modeling Hard Turning in Due Consideration of the Viscoplastic Asymmetry Effect

et al. 2015

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A novel material model for strain rate and temperature dependent asymmetric viscoplastic deformation behavior considering transformation induced plasticity (TRIP) as a crucial phenomenon influencing the hard turning process-oriented ductility was developed. Within the framework of viscoplasticity and continuum damage mechanics, the well-established Johnson-Cook flow stress model has been upgraded by the concept of weighting functions accounting for the asymmetric viscoplastic material behavior under different stress conditions during hard machining of chrome bearing steel AISI 52100. Moreover, the extended Johnson-Cook model incorporates the ductility alteration caused by transformation induced plasticity by applying the Leblond-approach. Based on the theoretical proceeding, a material routine for flow stress computation considering the viscoplastic asymmetry has been developed and applied within hard turning simulations using the commercial Finite-Element-Method (FEM) software DEFORM. In addition, the hard turning simulation model accounts for the phase transitions between martensite and austenite during the process-related material heating as well as austenite and white layer as a consequence of the so-called reverse martensite transformation. A decisive actuating variable concerning the feasibility and accuracy of the performed hard turning modelling is the austenite start temperature, which has been determined in consideration of the externally applied stress. Within the scope of the material modelling, a novel quantity referred to as stress mode factor has been introduced in order to enable the identification of areas in the cutting zone subjected to heterogeneous load conditions. The stress mode factor appraisal within the aforementioned bearing steel material routine discloses a new path to establish the influence of dissimilar stress states on the work piece heat balance as well as the impact of transformation induced plasticity on the stress distribution in the cutting zone.

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Section: Methodsmentioning

confidence: 99%

A Novel Finite Element Approach to Modeling Hard Turning in Due Consideration of the Viscoplastic Asymmetry Effect

et al. 2015

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“…• The parameters of Johnson Cook's law A, B, n, C, and m for the different phases are taken from (Biermann et al 2010) and (Hor et al 2013).…”

Section: En-51crv4 Propertiesmentioning

confidence: 99%

Thermo-mechanical and metallurgical model of leaf spring industrial quenching process

Slama

Jabeur

Mansouri

et al. 2021

Preprint

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This study is a numerical analysis of the industrial quenching process for leaf springs developed by the CAVEO company. The leaf chosen for this study is of a parabolic profile made of EN-51CrV4 steel (AISI 6150). The aim of this study is to set up a numerical model to predict thermal, metallurgical, and mechanical behavior of a leaf spring from exit of the heating furnace to exit of the quenching bath going through a cambering operation. This study would therefore allow the company to switch from a development scheme based on experiments using physical prototypes tested on the production line to a new scheme based on virtual prototypes using numerical simulation. The development of the numerical model using the finite element method is carried out using the ABAQUS/Implicit solver coupled with two user subroutines Phase and UMAT. The first one have been developed to compute microstructure evolution and the second one to define the constitutive law taking into account phase transformations. This model helps us to follow the spatio-temporal evolutions of temperature and microstructure in the leaf, as well as the variation of the leaf deflection during the process. The proposed numerical model is supported by an experimental protocol based on infrared thermographic images, Rockwell-C hardness measurements, metallographic observations, and deflection measurements. Indeed, the results of the proposed thermo-mechanical and metallurgical model are closed to experimental results.

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“…Up to now, the determination of forces and temperatures has been realized within the FEsimulation of the machining process. Nowadays even the prediction of tool wear is possible [2,3,4,5]. Only little work has been done to predict the thermal influence on the part's components of the machining process [10,11].…”

Section: 1mentioning

confidence: 99%

FEA-Methodology for the Prediction of Aluminium Thin Walled Part Deformation in Dry Milling Operations

Puls

Klocke

Lung

et al. 2011

AMR

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The presented work is a part of the EU integrated and collaborative project “Aligning, Holding and Fixing Flexible and Difficult to Handle Components” (AFFIX). The deformation of thin-walled components, caused by a thermo-mechanical load in the machining process, is a common challenge in manufacturing automotive engine heads and gearboxes. Geometrical tolerances like flatness are strongly affected by the thermo-mechanical process loads, and therefore cause production scraps and serious engine faults in case of undetected defects. To avoid long process setup times, a methodology has been developed to calculate the resulting part flatness. Based on the developed methodology a clamping strategy has been identified which minimises the resulting part deformation in milling operations and thus ensures the accuracy and quality of thin-walled aluminum power train parts.

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Finite element modeling and three-dimensional simulation of the turning process incorporating the material hardness

Cited by 9 publications

References 4 publications

A Novel Finite Element Approach to Modeling Hard Turning in Due Consideration of the Viscoplastic Asymmetry Effect

A Novel Finite Element Approach to Modeling Hard Turning in Due Consideration of the Viscoplastic Asymmetry Effect

Thermo-mechanical and metallurgical model of leaf spring industrial quenching process

FEA-Methodology for the Prediction of Aluminium Thin Walled Part Deformation in Dry Milling Operations

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