Papers by Keyword: Orthogonal Cutting

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Authors: Zhao Yu Mou, Peng Fei Gao, Wei Fang Wang, Dong Hui Wen
Abstract: The purpose of this paper is to compare different simulation model of orthogonal cutting process using three different FEM commercial codes as well as with the results of orthogonal experiment. For one thing, element type, boundary condition and friction model between the chip and tool commercial have been compared when the numerical model established in implicit finite element code, Deform3D and the explicit code ANSYS/LS-DYNA and Thirdwave AdvantEdge. For another, main and thrust cutting forces, shear angles, chip thicknesses and contact lengths by three codes are compared with the orthogonal metal cutting experiment by Movahhedy and Altintas.
Authors: Jia Chun Wang, Na Li, Yun Peng Kou, Yu Lin Yang
Abstract: A better understanding of friction modeling is really important for producing more realistic finite element models of machining processes. This paper presents a methodology to determine the friction at the tool-chip interface. By matching the measured values of the cutting forces with the predicted results from finite element simulations (FEM), a revised friction model on the tool-chip interface is developed. Reasonable distribution of the stress, strain and strain-rate, as well as the temperature fields at the tool-chip interface could be achieved by using this approach. An attempt is made by FEM to obtain a full understanding of relationships between the complex physical behavior and friction at the tool-chip interface. It is found that the sticking-sliding separated area is located at the points with the greatest temperature. And the corresponding relationship between cutting parameters and sticking-sliding friction separated area is found.
Authors: Kun Xian Qiu, Ya Xing Bie, Sheng Qin, Qing Long An, Ming Chen
Abstract: High strength carbon fiber reinforced polymers (CFRP) with unidirectional laminate structure have gradually developed into major materials in load-bearing aerospace components, and the cutting demand of CFRP is increasing. In this work, orthogonal cutting tests were conducted on T700 high-strength CFRP laminates to get the mechanistic force model of special cutting tools. Also cutting force coefficients were obtained when cutting T700 high-strength CFRP laminates under different fiber orientations. Experimental results showed that the lowest cutting force was obtained when fiber orientation was between 120° and 150°.
Authors: Evaggelos Kaselouris, Theodoros Papadoulis, Elenh Variantza, Andreas Baroutsos, Vasilios Dimitriou
Abstract: The capability of the explicit numerical methods to simulate accurately the real cutting process is investigated in this research work. Smoothed particle hydrodynamics - SPH, classical Lagrangian finite element method - FEM and Multi-Material Arbitrary Lagrangian Eulerian - ALE methods are chosen for the modeling and simulation of the orthogonal metal cutting process of AISI H13 in LS-DYNA. The cutting tool is modeled as a rigid FEM body that incrementally penetrates into the flexible deformable workpiece. At each numerical model, the dynamic elastoplastic behavior of the workpiece material is investigated by taking into account the Johnson-Cook (J-C) constitutive strength material model. The influence of the J-C parameter values found in literature to the models is explored. The obtained numerical SPH, FEM and ALE results of the estimated cutting and thrust forces, stress, plastic strain and thermal distributions are compared with results found in the literature. This comparison, leads to valuable conclusions for the performance of the three methods, concerning the approximation accuracy, model development complexity and computational time demands. Based on these conclusions the SPH method is chosen to simulate the experimentally performed orthogonal cut of AISI 1045. The obtained SPH numerical results outline its advantages among the other explicit simulation methods.
Authors: Shu Tao Huang, Li Zhou, Jin Lei Wang
Abstract: Due to the superior mechanical and thermal properties of SiCp/Al composites, their poor machinability has been the main deterrent to their substitution for metal parts. Machining of SiCp/Al composites has been considerably difficult because the extremely abrasive nature of SiC reinforcements causes rapid tool wear. In this paper, an experiment was carried out to investigate the influence of the cutting speed, cutting depth and tool rake angle on cutting force during orthogonal machining of SiCp/Al composites. The results indicate that the cutting depth is one of the main cutting parameters that affect the cutting force, while the cutting speed and tool rake angle have no significant effects on the cutting force.
Authors: Fadi Kahwash, Islam Shyha, Alireza Maheri
Abstract: This paper presents an empirical force model quantifying the effect of fibre volume fraction and fibre orientation on the cutting forces during orthogonal cutting of unidirectional composites. Glass fibre plates and high speed steel cutting tools are used to perform orthogonal cutting on shaping machine whereas cutting forces are measured using platform force dynamometer. The analysis of forces shows almost linear dependency of cutting forces on the fibre content for both cutting and thrust forces. High dependency of cutting forces is also observed on fibre orientation with high percentage contribution ratio (up to 95.31%). Lowest forces corresponded to 30o and highest to 90o fibre orientation. Multivariate regression technique is used to construct the empirical model.
Authors: Ping Yuan, Hui Yue Dong
Abstract: A new finite element simulation model based on two trochoidal tool-paths was constructed, and was used to simulate a full immersed milling with three flutes cutter. In this FEM model, the special method used here is to construct two trochoidal curves at the beginning with an offset value which is just equal to the feed value per tooth. These two linked trochoidal curves represent tool paths generated by two flutes respectively so as to construct the workpiece model. Cutting forces in the feed direction and in the normal direction were analyzed in detail. A verifying experiment shows this simulation is credible in general. This method can also be applied into situations of milling with more flutes such as face milling.
Authors: Gianluca D'Urso, Aldo Attanasio
Abstract: The present paper reports the results obtained investigating surface work hardening in turning as a function of cutting speed, feed rate and tool wear. An experimental campaign was carried out using AISI 304 steel as workpiece material. Pipes 4 mm thick were machined under orthogonal cutting conditions. Tools with flat rake surface were adopted and dry cutting conditions were taken into account. Cutting speed and feed rate were varied and the tool wear was monitored using a CNC visiomeasuring machine. The tool wear was related to the workpiece strain hardening. Starting from micro Vickers test data, an analytical model representing the strain hardening behavior along a workpiece section was defined. In addition, a Fortran subroutine for the simulation of strain hardening by means of a 2D FEM code was implemented.
Authors: Qi Biao Yang, Zhan Qiang Liu, Zhen Yu Shi
Abstract: As the deformation of chip increases with cutting speed, the morphology of chip changes from continuous to serrated type. It is supposed that serrated chips generate due to adiabatic shear instability in the primary deformation zone. A new analytical model for predicting adiabatic shear critical condition in orthogonal cutting is proposed by considering cutting conditions and properties of workpiece material. It is found that the influence of shear strain on the onset of adiabatic shear could be neglected. The shear strain rate and temperature, however, play a leading role on the onset of adiabatic shear. At lower cutting speed the shear strain rate plays a dominant role while at higher cutting speed the situation is just the reverse. With the increase of cutting speed, the yield stress, material characteristic constant and uncut chip thickness will facilitate adiabatic shear instability, while the coefficient of strain rate hardening, coefficient of strain hardening, coefficient of thermal softening, thermal diffusivity and tool rake angle have negative effect on adiabatic shear instability.
Authors: Francesco Greco, Domenico Umbrello, Serena Di Renzo, Luigino Filice, I. Alfaro, E. Cueto
Abstract: FEM implicit formulation shows specific limitations in processes such as cutting, where large deformation results in a heavy mesh distortion. Powerful rezoning-remeshing algorithms strongly reduce the effects of such a limitation but the computational times are significantly increased and additional errors are introduced. Nodal Integration is a recently introduced technique that allows finite element method to provide more reliable results when mesh becomes distorted in traditional FEMs. Furthermore, volumetric locking phenomenon seems to be avoided by using this integration technique instead of other methods, such as the coupled formulations. In this paper, a comparison between a “classical” FEM simulation and the Nodal Integration one is carried out taking into account a simple orthogonal cutting process.
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