The advance of research on constitutive model used in finite element simulation of metal cutting

Abstract

Finite element simulation has become one of the research methods of metal cutting, and the constitutive model plays a decisive role in the modelling. Metal cutting has the characteristics of “three high”, namely large strain, high strain rate, and high temperature compared with other deformation process. An accurate constitutive model that can be used in the finite element simulation of metal cutting is difficult to obtain because the limitation of mechanical experiment. Therefore, the research of constitutive models used in the finite element simulation of metal cutting is summarized in this paper. Several typical constitutive models and their corrections are introduced firstly. Secondly, the main methods to obtain the constitutive parameters are introduced, and the problems of the methods are pointed out. Thirdly, some finite element simulations of serrated chip based on the constitutive models which modified by thermal softening, etc. are given, and the works on the research of the influence of model parameters are summarized. Fourthly, the constitutive parameters of several common materials are collected. The differences of them are shown and the reasons are analyzed. Finally, the problems in current research are analyzed and the directions of future development are pointed out. It can encourage the development of finite element simulation of metal cutting, especially for the simulation of serrated chip produced in high-speed cutting.

Failure analysis of spline coupling in an engine starting motor

“…The material of the internal spline is 45 steel, which the elastic modulus, yield strength and shear strength are 210 GPa, 355 MPa, and 600 MPa, respectively. [24][25][26] As described in Figure 1(d), the failure area of internal spline is mainly concentrated on bottom land and two end faces. In addition, spline failure leads to the change of tooth surface morphology.…”

“…22,23 Due to the complex spline structure and stress characteristics in the working process, there is a deviation between the analytic study and the actual situation. [22][23][24] The formulas in the analytical method did not take into account the influence of uneven loading on the spline coupling. Moreover, empirical constants in the formula need to be selected within a certain range, which inevitably introduces the subjective uncertainty.…”