Finite element modeling of residual stresses in machining induced by cutting using a tool with finite edge radius

International Journal of Mechanical Sciences

Volumn 47, Issue 10, 2005, Pages 1611-1628

  Ee, K C ^a   Dillon Jr , O W ^a   Jawahir, I S ^a  

^a UNIVERSITY OF KENTUCKY   (United States)

Author keywords

Finite element method; Machining; Residual stresses

Indexed keywords

CUTTING TOOLS; DEFORMATION; FINITE ELEMENT METHOD; NON NEWTONIAN FLOW; RESIDUAL STRESSES; THERMOMECHANICAL TREATMENT; VISCOPLASTICITY;

CUTTING CONDITIONS; ELASTIC COMPONENTS; MATERIAL FLOW; UNLOADING PATHS;

MICROMACHINING;

EID: 23844469285     PISSN: 00207403     EISSN: None     Source Type: Journal    
DOI: 10.1016/j.ijmecsci.2005.06.001     Document Type: Article

References (47)

1. E. Brinksmeier, J.T. Carmmett, W. Konig, P. Leskovar, J. Peters, and H.K. Tonshoff Residual stresses - measurement and causes in machining processes. Keynote paper Annals of the CIRP 3 2 1982 491 510
2. W. König, A. Berktold, and K.-F. Koch Turning versus grinding - a comparison of surface integrity aspects and attainable accuracies Annals of the CIRP 42 1 1993 39 43
3. E.K. Henriksen Residual stresses in machined surfaces Transactions of the ASME January 1951 69 76
4. J.A. Bailey, S. Jeelani, and S.E. Becker Surface integrity in machining AISI 4340 steel Journal of Engineering for Industry August 1976 999 1007
5. C.R. Liu, and M.M. Barash The mechanical state of the sublayer of a surface generated by chip-removal process part 1: cutting with a sharp tool Transactions of the ASME November 1976 1192 1201
6. C.R. Liu, and M.M. Barash The mechanical state of the sublayer of a surface generated by chip-removal process part 2: cutting with a tool with flank wear Transactions of the ASME November 1976 1202 1208
7. C.R. Liu, and M.M. Barash Variables foverning patterns of mechanical residual stress in a machined surface Journal of Engineering for Industry 104 1982 257 264
8. Y. Matsumoto, M.M. Barash, and C.R. Liu Effect of hardness on the surface integrity of AISI 4340 steel Journal of Engineering for Industry 108 1986 169 175
9. J.R. Davis ASM specialty handbook: carbon and alloy steels 1996 ASM International Material Parks
10. D.W. Wu, and Y. Matsumoto The effects of hardness on residual stresses in orthogonal machining of AISI 4340 steel Journal of Engineering for Industry 112 1990 245 252
11. Q. Xie, A.E. Bayoumi, A.L. Kendall, and G.L. Sheldon A study on residual stresses and tool wear induced by machining processes Transactions of the NAMRC XVII 1989 170 174
12. Kuzinovski M, Pavlovski V, Zebrovski H, Cichos P. Residual stress in the surface layer of the machining surface by turning with ceramic cutting inserts. Third international conference on advanced manufacturing systems and technology (AMST) held at Udine, Italy 1993. p. 263-269.
13. E. Capello, P. Davoli, G. Bassanini, and A. Bisi Residual stresses and surface roughness in turning Journal of Engineering Materials and Technology 121 1999 348 351
14. R. M'Saoubi, J.C. Outeiro, B. Changeux, J.L. Lebrun, and A. Morão Dias Residual stress analysis in orthogonal machining of standard and resulfurized AISI 316L steels Journal of Materials Processing Technology 96 1999 225 233
15. J.C. Outerio, A.M. Dias, J.L. Lebrun, and V.P. Astakhov Machining residual stresses in AISI 316L steel and their correlation with the cutting parameters Machining Science and Technology 6 1 2002 251 270
16. K. Ueda, K. Manabe, and J. Okida A survey and recent investigations on computational mechanics in cutting International Journal of Forming Processes 3 1-2 2000 37 58
17. J. Mackerle Finite-element analysis and simulation of machining: a bibliography (1976-1996) Journal of Materials Processing Technology 86 1-3 1998 17 44
18. J. Mackerle Finite element analysis and simulation of machining: an addendum: a bibliography (1996-2002) International Journal of Machine Tools and Manufacture 43 1 2003 103 114
19. A.J. Shih, and T.Y. Yang Experimental and finite element predictions of residual stresses due to orthogonal metal cutting International Journal for Numerical Methods in Engineering 36 1993 1487 1507
20. H. Sasahara, T. Obikawa, and T. Shirakashi FEM analysis of cutting sequence effect on mechanical characteristics in machined layer Journal of Materials Processing Technology 62 1996 448 453
21. T. Obikawa, H. Sasahara, T. Shirakashi, and E. Usui Application of computational machining method to discontinuous chip formation Journal of Manufacturing Science and Engineering 119 1997 667 674
22. Z.C. Lin, W.L. Lai, H.Y. Lin, and C.R. Liu Residual stresses with different tool flank wear lengths in the ultra-precision machining of Ni-P alloys Journal of Material Processing and Technology 65 1-3 1997 116 126
23. Z.C. Lin, W.L. Lai, H.Y. Lin, and C.R. Liu The study of ultra-precision machining and residual stress for NiP alloy with different cutting speeds and depth of cut Journal of Material Processing and Technology 97 1-3 2000 200 210
24. C.R. Liu, and Y.B. Guo Finite element analysis of the effect of sequential cuts and tool-chip friction on residual stresses in a machined layer International Journal of Mechanical Sciences 42 2000 1069 1086
25. Y.B. Guo, and C.R. Liu FEM analysis of mechanical state on sequentially machined surfaces Machining Science and Technology 6 1 2002 21 42
26. C. Shet, and X. Deng Residual stresses and strains in orthogonal metal cutting International Journal of Machine Tools & Manufacture 43 2003 573 587
27. Marusich TD, Askari E. Modeling residual stress and workpiece quality in machined surfaces. Fourth CIRP international workshop modeling of machining operations, held at Technological University, Delft, 2001. p.105-109.
28. Lundblad M. Influence of cutting speed on residual stresses in the work piece. Second international seminar on improving machine tool performance, held at La Baule, France, July 3-5, 2000, CD-ROM.
29. J.S. Strenkowski, and J.T. Carroll III A finite element model of orthogonal metal cutting Journal of Engineering for Industry 107 1985 349 354
30. J.M. Huang, and J.T. Black An evaluation of chip separation criteria for the FEM simulation of machining Journal of Manufacturing Science and Engineering 118 1996 545 554
31. T.D. Marusich, and M. Ortiz Modeling and simulation of high-speed machining International Journal for Numerical Methods in Engineering 38 1995 3675 3694
32. G.R. Johnson, and W.H. Cook Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures Engineering Fracture Mechanics 21 1 1985 31 48
33. E.-G. Ng, T.I. El-Wardany, M. Dumitrescu, and M.A. Elbestawi Physics-based simulation of high speed machining Machining Science and Technology 6 3 2002 301 330
34. G.S. Sekhon, and J.L. Chenot Numerical simulation of continuous chip formation during non-steady orthogonal cutting Engineering Computations 10 1993 31 48
35. E. Ceretti, P. Fallbohmer, W.T. Wu, and T. Altan Application of 2D FEM to chip formation in orthogonal cutting Journal of Materials Processing and Technology 59 1996 169 180
36. S. Kumar, P. Fallböhmer, and T. Altan Computer simulation of orthogonal metal cutting processes: determination of material properties and effects of tool geometry on chip flow Technical Papers of NAMRI/SME XXV/177 1997 1 6
37. T. Özel, and T. Altan Determination of workpiece flow stress and friction at the chip-tool contact for high-speed cutting International Journal of Machine Tools & Manufacturing 40 2000 133 152
38. G.I. Taylor, and H. Quinney The latent energy in a metal after working Proceedings of the Royal Society of London A 413 1934 307 326
39. F. Meslin, and J.C. Hamann Definition of constitutive equations and friction by inverse method and machining tests International Workshop of Friction and Flow Stress in Cutting and Forming held at ENSAM, Paris, January 25th-26th 2000 135 157
40. www.matweb.com.
41. P.L.B. Oxley The mechanics of machining: an analytical approach to assessing machinability 1989 Wiley New York
42. M.M. Rashid Incremental kinematics for finite element applications International Journal for Numerical Methods in Engineering 36 1993 3937 3956
43. T. Belytschko, and W.E. Bachrach Efficient implementation of quadrilaterals with high coarse-mesh accuracy Computer Methods in Applied Mechanics and Engineering 54 1986 279 301
44. D.Y. Kwak, J.S. Cheon, and Y.T. Im Remeshing for metal forming simulations - Part I: two-dimensional quadrilateral remeshing International Journal of Numerical Mechanics and Engineering 53 2002 2463 2500
45. T. Sussman, and K.J. Bathe A finite element for nonlinear incompressible elastic and inelastic analysis Computers & Structures 26 1987 357 409
46. J.C. Nagtegaal, D.M. Parks, and J.C. Rice On numerically accurate finite element solutions in the fully plastic range Computer Methods in Applied Mechanics and Engineering 4 1974 153 178
47. T. Belytschko, W.K. Liu, and B. Moran Nonlinear finite elements for Continua and structure: Chapter 8 element technology 2000 Wiley New York