Predicting Continuous Chip to Segmented Chip Transition in Orthogonal Cutting of C45E Steel through Damage Modeling

Abstract

Machining process modeling has been an active endeavor for more than a century and it has been reported to be able to predict industrially relevant process outcomes. Recent advances in the fundamental understanding of material behavior and material modeling aids in improving the sustainability of industrial machining process. In this work, the flow stress behavior of C45E steel is modeled by modifying the well-known Johnson-Cook model that incorporates the dynamic strain aging (DSA) influence. The modification is based on the Voyiadjis-Abed-Rusinek (VAR) material model approach. The modified JC model provides the possibility for the first time to include DSA influence in chip formation simulations. The transition from continuous to segmented chip for varying rake angle and feed at constant cutting velocity is predicted while using the ductile damage modeling approach with two different fracture initiation strain models (Autenrieth fracture initiation strain model and Karp fracture initiation strain model). The result shows that chip segmentation intensity and frequency is sensitive to fracture initiation strain models. The Autenrieth fracture initiation strain model can predict the transition from continuous to segmented chip qualitatively. The study shows the transition from continuous chip to segmented chip for varying feed rates and rake angles for the first time. The study highlights the need for material testing at strain, strain rate, and temperature prevalent in the machining process for the development of flow stress and fracture models.

The Influence of Cutting Parameters on Plastic Deformation and Chip Compression during the Turning of C45 Medium Carbon Steel and 62SiMnCr4 Tool Steel

“…This steel is known as the so-called standard in determining machinability but also for other characteristics of the cutting process such as cutting forces and cutting temperature, e.g., in [55]. In addition, there is not only experimental work on this steel but also work in the field of modelling and simulation of the cutting process for this steel, e.g., in [39] analysis was made for this steel. In this article, the flow stress behaviour of C45E steel was modelled by modifying the Johnson-Cook model that incorporates the dynamic strain aging (DSA) influence.…”

“…In addition to turning, milling, and drilling, cutting zone research continues for a variety of other materials [38,39] and cutting technologies such as grinding [40], milling with a disc cutter [41], and Micro and Macro Machining (MMM) [42,43] by using FEM [44] and fuzzy algorithms [45].…”

Characterisation, Performance and Optimisation of Nanocellulose Metalworking Fluid (MWF) for Green Machining Process

“…This is observed with the use of conventional coolant. The arc chip size gets longer without breaking due to the high heat generated from greater friction and cutting force, thus causing a continuous chip [78]. Conventional coolant does not effectively caries away heat generated due to the high cutting speed.…”

Metal Machining—Recent Advances, Applications, and Challenges

“…Even though the chip looked very similar for both cases, the developed method showed that the obtained results were significantly different, showing how this methodology can be useful in other analyses. On the other hand, the work entitled "Predicting Continuous Chip to Segmented Chip Transition in Orthogonal Cutting of C45E Steel through Damage Modeling" performed by Devotta et al [35] integrated dynamic strain aging in the Johnson-Cook model, which is usually used to modelling machining processes, while also using the Voyiadjis-Abed-Rusinek approach. In this way, it became possible to predict the transition from a continuous chip to a discontinuous chip regarding the widely used C45E steel, depending on the rake angle and feed rate while keeping the cutting speed constant.…”