Finite element simulation of high-speed cutting forces

Journal of Materials Processing Technology

Volumn 176, Issue 1-3, 2006, Pages 117-126

  Bäker, Martin ^a  

^a TECHNICAL UNIVERSITY OF BRAUNSCHWEIG   (Germany)

Author keywords

Chip formation; Cutting speed; Finite element simulation; Machining

Indexed keywords

COMPUTER SIMULATION; FINITE ELEMENT METHOD; FRICTION; PLASTIC FLOW; SHEAR STRESS; THERMAL EFFECTS;

CHIP FORMATION; CHIPS; CUTTING SPEED; FINITE ELEMENT SIMULATION;

METAL CUTTING;

EID: 33744516584     PISSN: 09240136     EISSN: None     Source Type: Journal    
DOI: 10.1016/j.jmatprotec.2006.02.019     Document Type: Article

References (32)

1. In: Schulz H. (Ed). Scientific Fundamentals of HSC (2001), Carl Hanser Verlag, München
2. In: Tönshoff H.-K., and Hollmann F. (Eds). Spanen Metallischer Werkstoffe bei hohen Geschwindigkeiten (2000), Deutsche Forschungsgemeinschaft, Bonn
3. Childs T.H.C., Maekawa K., Obikawa T., and Yamane Y. Metal Machining-Theory and Applications (2000), Arnold, London
4. König W., Lowin R., Steffens K., and Hann V. Aspekte zur Technologie der Hochgeschwindigkeitszerspanung. Industrieanzeiger 103 (1981) 14-20
5. Marusich T.D., and Ortiz M. Modeling and simulation of high-speed machining. Int. J. Numer. Meth. Eng. 38 (1995) 3675-3693
6. Ceretti E., Lucchi M., and Altan T. FEM simulation of orthogonal cutting: serrated chip formation. J. Mater. Process. Technol. 95 (1999) 17-26
7. Chuzhoy L., DeVor R.E., Kapoor S.G., Beaudoin A.J., and Bamman D.J. Machining simulation of ductile iron and its constituents. Part 1. Estimation of material model parameters and their validation. J. Eng. Ind. 125 (2003) 181-191
8. Chuzhoy L., DeVor R.E., and Kapoor S.G. Machining simulation of ductile iron and its constituents. Part 2. Numerical simulation and experimental validation of machining. J. Eng. Ind. 125 (2003) 192-201
9. Mackerle J. Finite-element analysis and simulation of machining: a bibliography (1976-1996). J. Mater. Process. Technol. 86 (1999) 17
10. Mackerle J. Finite element analysis and simulation of machining: an addendum-a bibliography (1996-2002). Int. J. Mach. Tools Manuf. 43 (2003) 103
11. Sievert R., Noack H.-D., Hamann A., Löwe P., Singh K.N., Künecke G., Clos R., Schreppel U., Veit P., Uhlmann E., and Zettier R. Simulation der Spansegmentierung beim Hochgeschwindigkeits-Zerspanen unter Berücksichtigung duktiler Schädigung. Technische Mechanik 23 (2003) 216-233
12. Hill R. The mechanics of machining: a new approach. J. Mech. Phys. Solids 3 (1954) 47-53
13. Bäker M. On the role of energy in chip formation. Proc. Appl. Math. Mech. 2 (2003) 222-223
14. HKS Inc., USA ABAQUS/Standard User's Manual, Version 5.8, 1998.
15. Bäker M., Rösler J., and Siemers C. A finite element model of high speed metal cutting with adiabatic shearing. Comput. Struct. 80 (2002) 495-513
16. Sekhon G.S., and Chenot J.L. Numerical simulation of continuous chip formation during non-steady orthogonal cutting. Eng. Comput. 10 (1993) 31-48
17. Huang J.M., and Black J.T. An evaluation of chip separation criteria for the FEM simulation of machining. J. Manuf. Sci. Eng. 118 (1996) 545-554
18. Bäker M., Rösler J., and Siemers C. The influence of thermal conductivity on segmented chip formation. Comput. Mater. Sci. 26 (2003) 175-182
19. A. Gente, Merkmale der Spanbildung von TiAl6V4 und Ck45 bei sehr hohen Schnittgeschwindigkeiten, PhD Thesis, Technische Universität Braunschweig, Braunschweig, 2002.
20. Obikawa T., and Usui E. Computational machining of titanium alloy-finite element modeling and a few results. J. Manuf. Sci. Eng. 118 (1996) 208-215
21. Özel T., and Altan T. Process simulation using finite element method-prediction of cutting forces, tool stresses and temperatures in high-speed flat end milling. Int. J. Mach. Tools Manuf. 40 (2000) 713-738
22. Bäker M. Finite element investigation of the flow stress dependence of chip formation. J. Mater. Process. Technol. 167 (2005) 1-13
23. El-Magd E., and Treppmann C. Dehnratenabhängige Beschreibung der Fließkurven für erhöhte Temperaturen. Zeitschrift für Metallkunde 92 (2001) 888-893
24. Recht R.F. Catastrophic thermoplastic shear. J. Appl. Mech. 31 (1964) 189-193
25. H.K. Tönshoff, T. Friemuth, R. Ben Amor, J. Plöger, Characterizing the HSC-Range-Material Behaviour and Residual Stress, pp. 103-112 (in Schulz [1], 2001).
26. Merchant M.E. Mechanics of the metal cutting process. I. Orthogonal cutting and a type 2 chip. J. Appl. Phys. 16 (1945) 267-275
27. Oxley P.L.B. A strain-hardening solution for the "shear angle" in orthogonal metal cutting. Int. J. Mech. Sci. 3 (1961) 68-79
28. Oxley P.L.B. Mechanics of Machining (1989), Ellis Horwood Ltd., Chichester
29. Dewhurst P. On the non-uniqueness of the machining process. Proc. Roy. Soc. Lond., Ser. A 360 (1978) 587-610
30. Shih A.J. Finite element analysis of orthogonal metal cutting mechanics. Int. J. Mach. Tools Manuf. 36 (1996) 255-273
31. V. Zinkann, Der Spanbildungsvorgang als Acoustic-Emission-Quelle, PhD Thesis, RWTH Aachen, Shaker Verlag, 1999.
32. Kumar A., Hauser F.E., and Dorn J.E. Viscous drag on dislocations in aluminium at high strain rates. Acta Metall. 16 (1968) 1189-1197