Inverse Analysis Procedure to Determine Flow Stress and Friction Data for Metal Cutting Finite Element Modeling

Abstract

This paper describes an automated procedure developed for the identification of Johnson-Cook (JC) law material parameters and Coulomb friction coefficient at the tool-chip interface, in the specific case of metal cutting FE analysis. The procedure has been developed in iSight environment, through the integration between AdvantEdge metal cutting FE code and an appropriately selected optimization algorithm. The identification of JC and friction parameters, in fact, has been performed considering it as an optimization problem, in which the objective function is the numerical/experimental error function minimization (in the specific case, it is related to the forces and temperatures responses). The calibration and validation phases have been performed using forces and temperatures experimental data, collected in orthogonal cutting test on SAF2507 superduplex steel.

Cutting Force Prediction Models by FEA and RSM When Machining X56 Steel with Single Diamond Grit

“…A two-dimensional finite element machining model for X56 steel was performed by AdvantEdge as the 2D machining model has diverged from the 3D machining process [ 31 ]. Therefore, the approach features few uncertainties present with this conversion is economical and highly reliable [ 32 ]. AdvantEdge is a software designed for metal cutting simulation [ 32 , 33 ], the finite element simulation process diagram of which is shown in Figure 6 .…”

“…Therefore, the approach features few uncertainties present with this conversion is economical and highly reliable [ 32 ]. AdvantEdge is a software designed for metal cutting simulation [ 32 , 33 ], the finite element simulation process diagram of which is shown in Figure 6 . Diamond (polycrystalline diamond) was picked as the material of the diamond grits, and X56 steel was chosen as the workpiece material.…”