Papers by Author: Sha Liu

Abstract: This paper proposes a method to simulate residual stress induced by end milling process via 3-D FEM. First, Johnson-Cook material model parameters for a Japanese type of alloy steel (SCM440H) were extracted by a combination method. With the material model parameters, symmetrical end milling process for plate of SCM440H was simulated by FE software to get the residual stress distribution in the machined workpiece. Residual stress measurement experiment was carried out after end milling process to be compared with simulation result to verify the method, which proved that high simulation accuracy can be obtained by extracted material model parameters.

Abstract: Material constitutive equation plays an important role in Finite Element Analysis (FEA) of metal cutting process. This paper proposes a method to obtain parameters for Power Law model of a Japanese type of alloy steel (SCM440H) for 3-D FEA of face milling process, involving pressure bar experiments and orthogonal metal cutting experiments. Since pressure bar test cannot reach the high strain rate occurred in cutting process, orthogonal cutting experiment was combined to obtain parameters for material model. By this method, the ideal parameters for FEA of the face milling process were finally determined. Face milling experiments were performed to verify the accuracy of the model built.