Abstract
A thorough control of the machining operations is essential to ensure the successful post-processing of additively manufactured components, which can be assessed through machinability tests endowed with numerical simulation of the metal cutting process. However, to accurately depict the complex metal cutting mechanism, it is not only necessary to develop robust numerical models but also to properly characterize the material behavior, which can be a long-winded process, especially for state-of-stress sensitive materials. In this paper, an efficient mechanical characterization methodology has been developed through the usage of both direct and inverse calibration procedures. Apart from the typical axisymmetric specimens (such as those used in compression and tensile tests), plane strain specimens have been applied in the constitutive law calibration accounting for plastic and damage behaviors. Orthogonal cutting experiments allowed the validation of the implemented numerical model for simulation of the metal cutting processes. Moreover, the numerical simulation of an industrial machining operation (longitudinal cylindrical turning) revealed a very reasonably prediction of cutting forces and chip morphology, which is crucial for the identification of favorable cutting scenarios for difficult-to-cut materials.
Highlights
The numerical simulation of metal cutting operations has become an everyday practice to assist in the design of better cutting tools and in the optimization of cutting conditions aiming to improve the performance of the machining processes
The quality of the numerical predictions in metal cutting simulation depends mainly on how accurate the constitutive models are to describe the tribo-thermomechanical response of the workpiece materials in a given application
This is of tremendous importance in a context of metal cutting simulation where plastic deformation, fracture, and friction occur under extreme conditions of strain, strain rate, temperature, and complex state-of-stress which make mechanical and tribological testing challenging and leading frequently to intricate the calibration of constitutive parameters by inverse analysis
Summary
The numerical simulation of metal cutting operations has become an everyday practice to assist in the design of better cutting tools and in the optimization of cutting conditions aiming to improve the performance of the machining processes. There should be a concern to simplify constitutive model data calibration, which limits the usage of unnecessary experimental and theoretical procedures This is not an obvious exercise since mechanical and tribological response under typical metal cutting conditions are highly nonlinear, influenced by temperature, state-of-stress invariants (e.g., hydrostatic pressure), and with strong rate dependencies [5]. Pin-on-disc tribometers are regularly employed despite the low contact pressure and existence of metallic oxides, different from the tribological condition in the tool-chip contact interface [7,8] Even though these traditional mechanical and tribological tests are not able to guarantee the desired accuracy, they are commonly used in the direct calibration of the model coefficients for metal cutting simulation. The validated numerical model has been successfully used in simulations of industrial turning operations performed on AMed 18Ni300 maraging steel
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