Influence of material parameters on serrated chip prediction in finite element modeling of chip formation Process

Abstract

A 2D Finite Element Model set up using the Arbitrary Lagrangian Eulerian (A.L.E) formulation proposed in Abaqus/Explicit© (v6.8) is employed to analyze the sensitivity to material input parameters and cutting speed when predicting serrated chip in cutting process. No artificial criterion is employed to create the chip or to initiate serrated chip formation. Results showed significant influence of the thermal parameters (thermal conductivity, specific heat and inelastic heat fraction) and material behaviour law (Johnson-Cook law coefficients) on the serrated chip phenomena, especially in the case of the thermal conductivity and specific heat, but as well for parameters no so mentioned in previous research like the strain hardening or the yield stress.