Implementation of Advanced Frictional Laws for Modelling of High Speed Machining

Abstract:

High-speed machining is submitted to economical and ecological constraints. Optimization of cutting processes must increase productivity, reduce tool wear and control residual stresses in the workpiece. Developments of numerical approaches to simulate accurately high-speed machining process are therefore necessary since in situ optimization is long and costly. To get this purpose, rheological behaviour of both antagonists and representative friction models at tool-chip interface has to be studied as encountered during high-speed machining process. The study is led with AISI 1045 steel and an uncoated carbide tool. An experimental device has been first designed to simulate the friction behaviour at the tool-chip interface only in the zone near the cutting edge. Several tests are then performed to provide experimental data and these data are used to define the friction coefficient versus to the contact pressure, the sliding velocity and the interfacial temperature by a new formulation frictional law given by Brocail et al (2010). A two-dimensional finite element model of orthogonal cutting is developed with Abaqus/explicit software. An Arbitrary Lagrangian-Eulerian (ALE) formulation is used to predict chip formation, temperature, chip-tool contact length, chip thickness, and cutting forces. This numerical model of orthogonal cutting is then validated by comparing these process variables to experimental and numerical results obtained by Filice et al. (2006). This model makes possible qualitative analysis of input parameters related to cutting process and frictional models. A sensitivity analysis has been performed on the main input parameters (coefficients of the Johnson-Cook law, contact and thermal parameters) with the finite element model. The interfacial law determined by Brocail et al (2010) is implemented on this finite element model of machining and leads to improve numerical approaches of machining. Nevertheless, even if this law enables to reduce results between experimental and numerical approaches, some differences are still substantial. The advanced friction law must be complemented for higher sliding velocities and this work using a new specific experimental device will be presented in the second part of this paper.

• Periodical: Key Engineering Materials (Volumes 554-557)
• Pages: 2021-2028
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.554-557.2021
• Online since: June 2013
• Authors: Yannick Senecaut, Michel Watremez, Damien Meresse, Laurent Dubar
• Keywords: Friction Models, Machining Models, Tool-Chip Interface

References

[1] L. Filice, F. Micari, S. Rizzuti, D. Umbrello, A critical analysis on the friction modelling in orthogonal machining, International Journal of Machine Tools & Manufacture. 47 (2006) 709-714.

DOI: 10.1016/j.ijmachtools.2006.05.007

[2] J. Brocail, M. Watremez, L.Dubar, Identification of a friction model for modelling of orthogonal cutting, International Journal of Machine Tools & Manufacture. 50 (2010) 807-814.

DOI: 10.1016/j.ijmachtools.2010.05.003

[3] H. Ben Abdelali, C. Claudin, J. Rech, W. Ben Salem, Ph. Kapsa, A. Dogui, Experimental characterization of friction coefficient at the tool–chip–workpiece interface during dry cutting of AISI 1045, Wear. 286-287 (2012) 108-115.

DOI: 10.1016/j.wear.2011.05.030

[4] T. Özel, T. Altan, Determination of workpiece flow stress and friction at the chip-tool contact for high-speed cutting, International Journal of Machine Tools & Manufacture. 40 (2000) 133-152.

DOI: 10.1016/s0890-6955(99)00051-6

[5] M. Shatla, C. Kerk, T. Altan, Process modeling in machining - part I: determination of flow stress data, International Journal of Machine Tools & Manufacture. 41 (2001) 1511-1534.

DOI: 10.1016/s0890-6955(01)00016-5

[6] N. Fang, Slip-line modeling of machining with a rounded-edge tool - part II: analysis of the size effect and the shear strain-rate, Journal of the Mechanics and Physics of Solids. 51 (2003) 743-762.

DOI: 10.1016/s0022-5096(02)00061-3

[7] K.C. Ee, O.W. Dillon Jr., I.S. Jawahir, Finite element modelling of residual stresses in machining induced by cutting using a tool with finite edge radius, International Journal of Mechanical Sciences. 47 (2005) 1611-1628.

DOI: 10.1016/j.ijmecsci.2005.06.001

[8] T. Özel, E. Zeren, A methodology to determine work material flow stress and tool-chip interfacial friction properties by using analysis of machining, Journal of Manufacturing Science and Engineering. 128 (2006) 119-129.

DOI: 10.1115/1.2118767

[9] C. Bonnet, F. Valiorgue, J. Rech, C. Claudin, H. Hamdi, J.M. Bergheau, P. Gilles, Identification of a friction model - Application to the context of dry cutting of an AISI 316L austenitic stainless steel with a TiN coated carbide tool, International Journal of Machine Tools & Manufacture. 48 (2008) 1211– 1223

DOI: 10.1016/j.ijmachtools.2008.03.011

[10] F.Zemzemi, J.Rech, W. Ben Salem, A. Dogui, P. Kapsa, Identification of a friction model at tool/chip/workpiece interfaces in dry machining of AISI4142 treated steels, Journal of Materials Processing Technology. 209 (2009) 3978-3990.

DOI: 10.1016/j.jmatprotec.2008.09.019

[11] J. Rech, C. Claudin, E. D'Eramo, Identification of a friction model - Application to the context of dry cutting of an AISI 1045 annealed steel with a TiN coated carbide tool, International Journal of Machine Tools & Manufacture. 42 (2009) 738– 744.

DOI: 10.1016/j.triboint.2008.10.007

[12] J. Brocail, M. Watremez, L. Dubar , B. Bourouga. High speed machining: a new approach to friction analysis at tool-chip interface. e. cueto, f. chinesta (ed.), esaform 2007, Zaragoza, Spain, (2007) pp.685-690.

DOI: 10.1063/1.2729592

[13] J. Brocail, M. Watremez, L. Dubar , B. Bourouga. Contact and friction analysis at tool-chip interface to high-speed machining. P. Boisse (Ed.), ESAFORM 2008, Lyon, France, (2008) pp.1-4.

DOI: 10.1007/s12289-008-0128-7

[14] M. Watremez, D. Meresse, L. Dubar, J. Brocail, Finite element modelling of orthogonal cutting: sensitivity analysis of material and contact parameters. International Journal of Simulation and Process Modelling. 7 (2012) 262-274.

DOI: 10.1504/ijspm.2012.049820

[15] P. Rosakis, A.J. Rosakis, G. Ravichandran, J. Hodowany, A thermodynamic internal variable model for the partition of plastic work into heat and stored energy metals, Journal of the Mechanics and the Physics of Solids. 15 (2000) 581-607.

DOI: 10.1016/s0022-5096(99)00048-4

[16] S.P.F.C. Jaspers, J.H. Dautzenberg, material behaviour in conditions similar to metal cutting: flow stress in the primary shear zone, Journal of Materials Processing Technology. 122 (2002) 322-330.

DOI: 10.1016/s0924-0136(01)01228-6

[17] V. Kalhori, Modeling and simulation of mechanical cutting, PhD thesis, University of Lunea Tekniska. 2001.

[18] W. Grzesik, P. Nieslony, Prediction of friction and heat flow in machining incorporating thermophysical properties of the coating-chip interface, Wear. 256 (2004) 108-117.

DOI: 10.1016/s0043-1648(03)00390-9