Modelling of temperature and forces when orthogonally machining hardened steel

Ng, Eugene; Aspinwall, D.K.; Brazil, Declan; Monaghan, John M.

doi:10.1016/s0890-6955(98)00077-7

Cited by 138 publications

(61 citation statements)

References 29 publications

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“…17b shows that temperatures are increasing with the cutting speed and feed rate. No experiments were performed to verify the results, however, the range of temperatures and behavior predicted by FE models are in agreement with similar studies on high speed turning of H13 (Ng et al, 1999;Ng and Aspinwall, 2002a;2002b). Only FE models are able to predict temperatures as the SPH solver utilized in this study is unable to perform coupled temperature displacement analysis.…”

Section:   supporting

confidence: 70%

Chip morphology predictions while machining hardened tool steel using finite element and smoothed particles hydrodynamics methods

Umer

Qudeiri

Ashfaq

2016

J. Zhejiang Univ. Sci. A

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Chip morphology predictions in metal cutting have always been challenging because of the complexity of the various multiphysical phenomena that occur across the tool-chip interface. An accurate prediction of chip morphology is a key factor in the assessment of a particular machining operation with regard to both tool performance and workpiece quality. Although finite element (FE) models are being developed over the last two decades, their capabilities in modeling correct material flow around the tool tip with shear localization are very limited. FE models with an arbitrary Lagrangian Eulerian (ALE) approach are able to simulate correct material flow around the tool tip. However, these models are unable to predict any shear localization based on material flow criteria. On the other hand, FE models with a Lagrangian formulation can simulate shear localization in the chip segments; they need to make use of a mesh-based chip separation criterion that significantly affects material flow around the tool tip. In this study a mesh-free method viz. smoothed particles hydrodynamics (SPH) is implemented to simulate shear localization in the chip while machining hardened steel. Unlike other SPH models developed by some researchers, this model is based on a renormalized formulation that can consider frictional stresses along the tool-chip interface giving a realistic chip shape and material flow. SPH models with different cutting parameters are compared with the traditional FE models and it has been found that the SPH models are good for predicting shear localized chips and do not need any geometric or mesh-based chip separation criteria.

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Section:   supporting

confidence: 70%

Chip morphology predictions while machining hardened tool steel using finite element and smoothed particles hydrodynamics methods

Umer

Qudeiri

Ashfaq

2016

J. Zhejiang Univ. Sci. A

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“…No experiments were performed to verify the results; however, the range of temperatures and behavior predicted by FE models are in agreement with similar studies on high speed turning of H13. 15,34,35 Only FE models are able to predict temperatures as the SPH solver utilized in this study is unable to perform coupled temperature displacement analysis. Figure 15 shows equivalent plastic strain (PEEQ) contour at feed rate of 0.25 mm/rev and cutting speed of 250 m/min obtained with FE and SPH models.…”

Section: Resultsmentioning

confidence: 99%

Assessment of finite element and smoothed particles hydrodynamics methods for modeling serrated chip formation in hardened steel

Umer

Mohammed

Qudeiri

2016

Advances in Mechanical Engineering

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This study aims to perform comparative analyses in modeling serrated chip morphologies using traditional finite element and smoothed particles hydrodynamics methods. Although finite element models are being employed in predicting machining performance variables for the last two decades, many drawbacks and limitations exist with the current finite element models. The problems like excessive mesh distortions, high numerical cost of adaptive meshing techniques, and need of geometric chip separation criteria hinder its practical implementation in metal cutting industries. In this study, a mesh free method, namely, smoothed particles hydrodynamics, is implemented for modeling serrated chip morphology while machining AISI H13 hardened tool steel. The smoothed particles hydrodynamics models are compared with the traditional finite element models, and it has been found that the smoothed particles hydrodynamics models have good capabilities in handling large distortions and do not need any geometric or mesh-based chip separation criterion.

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“…The cutting tool is assumed to be perfectly rigid and isothermal with a temperature set to 294 K. Heat transfer between the particles of the substrate was enabled by applying a heat conductivity coefficient κ = 44.5 W/(mK) for unalloyed steel taken from Ng et al (1999). The work of plastic deformation W p caused by the cutting tool is converted into heat with a Taylor-Quinney-coefficient of 1 as can be seen in Eqn.…”

Section: Heat Transfer In the Substrate And Interaction With The Cuttmentioning

confidence: 99%

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

Leroch¹,

Eder²,

Ganzenmüller³

et al. 2018

Preprint

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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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Modelling of temperature and forces when orthogonally machining hardened steel

Cited by 138 publications

References 29 publications

Chip morphology predictions while machining hardened tool steel using finite element and smoothed particles hydrodynamics methods

Chip morphology predictions while machining hardened tool steel using finite element and smoothed particles hydrodynamics methods

Assessment of finite element and smoothed particles hydrodynamics methods for modeling serrated chip formation in hardened steel

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

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