Evaluation of Present Numerical Models for Predicting Metal Cutting Performance And Residual Stresses

Efforts on numerical modeling and simulation of metal cutting operations continue to increase due to the growing need for predicting the machining performance. A significant number of numerical methods, especially the Finite Element (FE) and the Mesh-free methods, are being developed and used to simulate the machining operations. However, the effectiveness of the numerical models to predict the machining performance depends on how accurately these models can represent the actual metal cutting process in terms of the input conditions and the quality and accuracy of the input data used in such models. This article presents results from a recently conducted comprehensive benchmark study, which involved the evaluation of various numerical predictive models for metal cutting. This study had a major objective to evaluate the effectiveness of the current numerical predictive models for machining performance. Five representative work materials were carefully selected for this study from a range of most commonly used work materials, along with a wide range of cutting conditions usually found in the published literature. The differences between the predicted results obtained from the various numerical models using different FE and Mesh-free codes are evaluated and compared with those obtained experimentally.

[1]  J. Strenkowski,et al.  Finite element prediction of chip geometry and tool/workpiece temperature distributions in orthogonal metal cutting , 1990 .

[2]  Jürgen Fleischer,et al.  Modelling of the heat input for face-milling processes , 2010 .

[3]  Maan Aabid Tawfiq,et al.  A Finite Element Analysis of Orthogonal Machining Using Different Tool Edge Geometries , 2007, Engineering and Technology Journal.

[4]  Pedro J. Arrazola,et al.  Characterisation of friction and heat partition coefficients at the tool-work material interface in cutting , 2013 .

[5]  H. Kolsky.  An Investigation of the Mechanical Properties of Materials at very High Rates of Loading , 1949 .

[6]  G. R. Johnson,et al.  Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures , 1985 .

[7]  Meng Liu,et al.  Effect of tool nose radius and tool wear on residual stress distribution in hard turning of bearing steel , 2004 .

[8]  S. M. Athavale,et al.  FINITE ELEMENT MODELING OF MACHINING: FROM PROOF-OF-CONCEPT TO ENGINEERING APPLICATIONS , 1998 .

[9]  Fabrizio Micari,et al.  DEPENDENCE OF MACHINING SIMULATION EFFECTIVENESS ON MATERIAL AND FRICTION MODELLING , 2008 .

[10]  Ekkard Brinksmeier,et al.  Surface integrity in material removal processes: Recent advances , 2011 .

[11]  W. B. Palmer,et al.  Mechanics of Orthogonal Machining , 1959 .

[12]  G. Poulachon,et al.  Process Mechanics and Surface Integrity Induced by Dry and Cryogenic Machining of AZ31B-O Magnesium Alloy , 2013 .

[13]  David A. Puleo,et al.  Enhanced surface integrity of AZ31B Mg alloy by cryogenic machining towards improved functional performance of machined components , 2012 .

[14]  J. T. Black,et al.  An Evaluation of Chip Separation Criteria for the FEM Simulation of Machining , 1996 .

[15]  Durul Ulutan,et al.  Prediction of machining induced residual stresses in turning of titanium and nickel based alloys with experiments and finite element simulations , 2012 .

[16]  D. Umbrello,et al.  Experimental and numerical modelling of the residual stresses induced in orthogonal cutting of AISI 316L steel , 2006 .

[17]  V. Astakhov,et al.  The assessment of plastic deformation in metal cutting , 2004 .

[18]  M. Gadala,et al.  Simulation of the orthogonal metal cutting process using an arbitrary Lagrangian–Eulerian finite-element method , 2000 .

[19]  D. M. Tracey,et al.  On the ductile enlargement of voids in triaxial stress fields , 1969 .

[20]  Yuebin Guo,et al.  An internal state variable plasticity-based approach to determine dynamic loading history effects on material property in manufacturing processes , 2005 .

[21]  Paulo A.F. Martins,et al.  Electromagnetic Cam Driven Compression Testing Equipment , 2012 .

[22]  David A Puleo,et al.  Effect of cryogenic burnishing on surface integrity modifications of Co-Cr-Mo biomedical alloy. , 2013, Journal of biomedical materials research. Part B, Applied biomaterials.

[23]  P. L. B. Oxley,et al.  The Influence of Rate of Strain-Hardening in Machining: , 1961 .

[24]  Rachid M'Saoubi,et al.  Surface Integrity of H13 ESR Mould Steel Milled by Carbide and CBN Tools , 2006 .

[25]  Tom Childs,et al.  Finite element simulation of chip flow in metal machining , 2001 .

[26]  Aldo Attanasio,et al.  3D finite element analysis of tool wear in machining , 2008 .

[27]  Abdelwaheb Dogui,et al.  Identification of a friction model at tool/chip/workpiece interfaces in dry machining of AISI4142 treated steels , 2009 .

[28]  Tarek Mabrouki,et al.  Numerical and experimental study of dry cutting for an aeronautic aluminium alloy (A2024-T351) , 2008 .

[29]  T. Wierzbicki,et al.  A new model of metal plasticity and fracture with pressure and Lode dependence , 2008 .

[30]  Spfc Serge Jaspers.  Metal cutting mechanics and material behaviour , 1999 .

[31]  J. Sölter,et al.  Heat partitioning in dry milling of steel , 2012 .

[32]  Viktor P. Astakhov,et al.  Metal Cutting Mechanics, Finite Element Modelling , 2008 .

[33]  I. S. Jawahir,et al.  A numerical model incorporating the microstructure alteration for predicting residual stresses in hard machining of AISI 52100 steel , 2010 .

[34]  V.A.M. Cristino,et al.  Tribology in Metal Cutting , 2013 .

[35]  T. Özel,et al.  Investigations on the effects of friction modeling in finite element simulation of machining , 2010 .

[36]  Hédi Hamdi,et al.  A new approach for the modelling of residual stresses induced by turning of 316L , 2007 .

[37]  Yusuf Altintas,et al.  Analytical Prediction of Stability Lobes in Milling , 1995 .

[38]  I. S. Jawahir,et al.  Size-effects and Surface Integrity in Machining and Their Influence on Product Sustainability , 2008 .

[39]  V. Astakhov,et al.  MODELING OF THE CONTACT STRESS DISTRIBUTION AT THE TOOL-CHIP INTERFACE , 2005 .

[40]  J. Strenkowski,et al.  A Finite Element Model of Orthogonal Metal Cutting , 1985 .

[41]  V. Astakhov,et al.  A novel approach for determining material constitutive parameters for a wide range of triaxiality under plane strain loading conditions , 2013 .

[42]  Matthew A. Davies,et al.  Recent advances in modelling of metal machining processes , 2013 .

[43]  C. R. Liu,et al.  FEM ANALYSIS OF MECHANICAL STATE ON SEQUENTIALLY MACHINED SURFACES , 2002 .

[44]  D. Umbrello,et al.  The influence of Johnson–Cook material constants on finite element simulation of machining of AISI 316L steel , 2007 .

[45]  A. Atkins.  Modelling metal cutting using modern ductile fracture mechanics: quantitative explanations for some longstanding problems , 2003 .