Inverse Determination of Constitutive Equations and Cutting Force Modelling for Complex Tools Using Oxley's Predictive Machining Theory

Denkena, Berend; Grove, Thilo; Dittrich, Marc-André; Niederwestberg, D.; Lahres, M.

doi:10.1016/j.procir.2015.03.012

Cited by 33 publications

(21 citation statements)

References 10 publications

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“…With improved computer performance, inverse identification of material law parameters is now possible. However, validation of these simulations on a global scale remains excessively limited, and is achieved by comparing the cutting forces [3], the shear angle, or the chip morphology [4][5][6]. Post mortem data of the cut (shear angle, chip thickness) are primarily obtained by interrupting the process with a Quick Stop Device [7,8].…”

Section: Introductionmentioning

confidence: 99%

Kinematic Field Measurements During Orthogonal Cutting Tests via DIC with Double-frame Camera and Pulsed Laser Lighting

et al. 2017

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The measurement of machined-part strain fields induced by the cutting process remains a challenge because of the presence of highly intensive and localised strains. In this study, a high-speed double-frame imaging device with pulsed laser lighting is used in order to obtain sharp and highly resolved images during orthogonal cutting tests performed in an aluminium alloy. The displacement fields are then measured using a global Q4-digital-image-correlation (DIC) method and several strategies, facilitating calculation of the total displacements due to the cut, along with the residual strains in the machined part. Numerical procedures are developed to manage the removed material that disturbs the DIC. An automatic primary shear angle detection procedure using DIC is also proposed. Five different markings, which are produced via chemical etching and micro blasting, are applied to the observed surfaces. Their effects on the kinematic fields and the uncertainties are then studied. Three surface parameters are proposed as indicators for determining the surface preparation suitability for the DIC. The repeatability of the kinematic fields induced during the cutting process is studied, because of the ease with which testing can be performed. Finally, the plastically deformed layer engendered by the cutting process is measured using the calculated residual strains.

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Section: Introductionmentioning

confidence: 99%

Kinematic Field Measurements During Orthogonal Cutting Tests via DIC with Double-frame Camera and Pulsed Laser Lighting

et al. 2017

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“…The methods of the second group were developed in the last two decades and are used especially in the simulation of cutting processes [15][16][17][18][19][20][21]. According to the method of determination, the constants of the constitutive equation are corrected by fitting the flow curve.…”

Section: Establishing the Parameters Of The Constitutive Equationmentioning

confidence: 99%

“…For correcting the constants of the constitutive equations, different algorithms are used, such as a combined algorithm between cutting tests and Oxley's machining theory [16,17], the Levenberg-Marquardt algorithm [18], evolutionary computational [20] and genetic algorithms [30], the response surface methodology [31], etc. Apart from that, a direct simulation-based determination of the material model parameters is very often used by means of a design of experiments (DOE) analysis implemented in some commercial finite element method (FEM) program environments (see e.g., [17,19,21]).…”

Section: Establishing the Parameters Of The Constitutive Equationmentioning

confidence: 99%

“…Regarding the identification of the Johnson-Cook constitutive equation by using the inverse method, the five parameters (A, B, n, C and m) are established either simultaneously [16][17][18]20] or separately, i.e., first the parameters A, B and n for the respective strain rates and temperatures and then the parameters C and m [19,32]. Representing the effect of temperature, the parameter m is established either simultaneously with the parameter C due to the DOE study by comparing simulated and experimentally determined cutting tests [19] or separately by including Oxley's machining theory [32,33].…”

Section: Establishing the Parameters Of The Constitutive Equationmentioning

confidence: 99%

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Determination of Johnson–Cook Constitutive Parameters for Cutting Simulations

Storchak

Rupp

Möhring

et al. 2019

Metals

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The Johnson–Cook constitutive equation is very widely used for simulating cutting processes. Different methods are applied for establishing parameters of the constitutive equation. Based on the methods analysed in this study, two algorithms were worked out to determine the constitutive parameters for the prevailing conditions during cutting processes. In the first algorithm, all constitutive parameters were established simultaneously with standardized test methods. In the second algorithm, the constitutive parameters were established separately in accordance with the cutting conditions prevailing in machining processes. The developed methodology was verified with AISI 1045 heat-treatable steel and Ti10V2Fe3Al (Ti-1023) titanium alloy. The two materials were examined in standardized tensile and compression tests with varying strain rates and temperatures. In addition, the kinetic characteristics of the orthogonal cutting process were established. Based on the results obtained by experiment and the algorithms developed, the constitutive parameters for the cutting conditions were calculated. The parameters were used to determine the material model for simulating the orthogonal cutting process. The algorithms developed were verified by comparing the simulated and experimentally determined kinetic cutting characteristics, which confirmed their good quality.

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“…The influence of tool wear was subsequently taken into account in Afazov et al (2013). Denkena et al (2015) developed an inverse determination methodology based on Oxley's machining theory to predict cutting forces for complex three-dimensional tools. When combined with tensile test data, material parameters could be determined using this method.…”

Section: Introductionmentioning

confidence: 99%

Development and validation of a meshless 3D material point method for simulating the micro-milling process

Leroch

Eder

Ganzenmüller

et al. 2018

Journal of Materials Processing Technology

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A meshless Generalized Interpolation Material Point Method for simulating the micro-milling process was developed. This method has several advantages over well-established approaches (such as finite elements) when it comes to large plastic strains and deformations, since it inherently does not suffer from tensile instability problems. The feasibility of the developed material point model for simulating micro-milling is verified against finite element simulations and experimental data. The model is able to successfully predict experimentally measured cutting forces and determine chip temperatures in agreement with conventional finite element simulations. After having verified the approach, the model was applied to perform extensive numerical 3D simulations of the micro-milling process. The goal is to evaluate the response of the micromilling cutting forces as function of the hardening behavior of the micro-milled material. The meshless 3D simulations reveal a dependency of tool force slopes (with respect to the uncut chip thickness) on the hardening parameters. Based on these findings, a new approach is outlined to determine hardening parameters directly from two micro-milling experiments with distinct, sufficiently large uncut chip thicknesses.

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Inverse Determination of Constitutive Equations and Cutting Force Modelling for Complex Tools Using Oxley's Predictive Machining Theory

Cited by 33 publications

References 10 publications

Kinematic Field Measurements During Orthogonal Cutting Tests via DIC with Double-frame Camera and Pulsed Laser Lighting

Kinematic Field Measurements During Orthogonal Cutting Tests via DIC with Double-frame Camera and Pulsed Laser Lighting

Determination of Johnson–Cook Constitutive Parameters for Cutting Simulations

Development and validation of a meshless 3D material point method for simulating the micro-milling process

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