Papers by Author: B. Lan

Abstract: This paper proposes a method of determining the constitutive equation parameters of a Japanese type of alloy steel (SCM440H) for Finite Element Analysis (FEA) of orthogonal cutting, involving pressure bar experiments, orthogonal metal cutting experiments and FEA inverse identification. First, Split Hopkinson Pressure Bar (SHPB) experiments combined with Quasi-Static pressure tests were conducted, and after analyzing and processing the experimental data, one set of original constitutive constants was obtained; in the mean time, orthogonal cutting experiments were also performed to collect the cutting force data. Then the original constants were put into FEA software to simulate the cutting process. But comparison between the orthogonal cutting experimental and the simulation results revealed the inadequacy for the constants to predict cutting forces. To address this problem, an inverse identification method was employed to optimize the constants iteratively. And after a certain number of iterations, the ideal parameters for FEA of the orthogonal cutting process were finally determined.

Abstract: Identification of workpiece material constitutive parameters for their application in the simulation of metal cutting process has been a hot research spot for long. This paper proposes a methodology to address this problem using orthogonal cutting tests and Genetic Algorithm (GA). First, an analytical model which calculates the dynamic characteristics occurring in the primary shear zone is introduced; then, orthogonal cutting tests are carried out, to record the following mechanical characteristics with the analytical model: shear stresses, shear strains, strain rates, cutting temperatures; afterwards, GA is employed to obtain the constitutive parameters from these characteristics; at last, the finite element method (FEM) simulations of the cutting tests are performed to evaluate the predictive accuracies of the obtained parameters. In this paper, a Japanese brand steel SCM440H is used as the workpiece material, and the simulation results of its constitutive parameters show good agreements with the experimental data, which renders the feasibility of the proposed methodology.