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

Watremez, Michel; Méresse, Damien; Dubar, Laurent; Brocail, Julien

doi:10.1504/ijspm.2012.049820

Cited by 6 publications

(6 citation statements)

References 15 publications

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“…Watremez et Al (2012) [14] have also study the sensitivity of process parameters to input parameters with a numerical model of orthogonal cutting. This analysis shows that the friction coefficient has a main impact on the process variables.…”

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

View full text Add to dashboard Cite

show abstract

“…Finite element methods have been used in this context to numerically compute the different fields associated with physical problems and enable the analysis of their parameters [6].…”

Section: Introductionmentioning

confidence: 99%

Simulation of Cracks Detection in Tubes by Eddy Current Testing

Bennoud

Zergoug²

2016

IJM

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“…Very high pressures combined with sliding localized at the tool tip and on the cutting face speeds activate specific physical phenomena. Most studies on machining modeling as works of Watremez et Al in 2012 [1], Brocail et Al in 2010 [2] or Rech et al in 2009 [3] are conducted with a rheological Johnson-Cook model determined by Jaspers and Dautzenberg in 2002 [4]. However, this rheological model doesn't include microstructural phenomena which can occur in the tool-chip interface.…”

Section: Introductionmentioning

confidence: 99%

“…Watremez and al [1] have also led study of the sensitivity of input parameters on predicted output parameters in numerical machining modeling. This analysis shows a significant effect of input friction coefficient on predicted cutting process parameters.…”

mentioning

confidence: 99%

Dynamic Recrystallization Observed at the Tool/Chip Interface in Machining

Senecaut

Watremez

Brocail

et al. 2015

KEM

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In numerical approaches for high speed machining, the rheological behavior of machined materials is usually described by a Johnson Cook law. However, studies have shown that dynamic recrystallization phenomena appear during machining in the tool/chip interface. The Johnson Cook constitutive law does not include such phenomena. Thus, specific rheological models based on metallurgy are introduced to consider these dynamic recrystallization phenomena. Two empirical models proposed by Kim et al. (2003) and Lurdos (2008) are investigated in machining modeling. A two-dimensional finite element model of orthogonal cutting, using an Arbitrary Lagrangian-Eulerian (ALE) formulation, is developed with the Abaqus/explicit software. Specific rheological models are implemented in the calculation code thanks to a subroutine. This finite element model can then predict chip formation, interfacial temperatures, chip-tool contact length, cutting forces and chip thickness with also and especially the recrystallized area. New specific experiments on an orthogonal cutting test bench are conducted on AISI 1045 steel specimens with an uncoated carbide tool. Many tests are performed and results are focused on total chip thicknesses and recrystallized chip thicknesses. Finally, compared to numerical results got with a Johnson Cook law, numerical results obtained using specific rheological models to take into account dynamic recrystallization phenomena are very close to experimental results. This work shows also the influence of rheological behavior laws on predicted results in the modeling of high speed modeling.

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

Cited by 6 publications

References 15 publications

Implementation of Advanced Frictional Laws for Modelling of High Speed Machining

Implementation of Advanced Frictional Laws for Modelling of High Speed Machining

Simulation of Cracks Detection in Tubes by Eddy Current Testing

Dynamic Recrystallization Observed at the Tool/Chip Interface in Machining

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