Flow Stress Optimization for Machining Simulations

K.S. Vijay Sekar; Kumar M. Pradeep

doi:10.4028/www.scientific.net/AMR.622-623.91

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HomeAdvanced Materials ResearchAdvanced Materials Research Vols. 622-623Flow Stress Optimization for Machining Simulations

Flow Stress Optimization for Machining Simulations

Abstract:

Flow stress is a vital input data for machining simulations, which is experimentally measured from Split Hopkinson pressure bar (SHPB) tests. However such flow stress does not fit machining conditions of strain, strain rate and temperatures and lead to serious simulation errors. In this research work an integrated Taguchi – Finite element (FE) methodology is adopted to optimize the flow stress of AISI 1045 steel material for orthogonal machining. The flow stress computed from the optimization approach along with thermo physical material properties are input into the FE code. The FE cutting forces and chip thickness ratio (CTR) showed an improvement of 6-8% and 2-4% over conventional Johnson – Cook (JC) models. An optimum set of JC model parameters were found from the study. The JC parametric analysis indicated high cutting force sensitivity to yield strength and CTR sensitivity to yield strength, strain hardening and thermal softening.

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Periodical:

Advanced Materials Research (Volumes 622-623)

Pages:

91-98

DOI:

https://doi.org/10.4028/www.scientific.net/AMR.622-623.91

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Online since:

December 2012

Authors:

K.S. Vijay Sekar, Kumar M. Pradeep

Keywords:

Finite Element (FE) Simulation, Flow Stress, Optimization, Orthogonal Machining, Taguchi

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