Abstract
One of the main problems that exists when working with Finite Element Methods (FEM) applied to machining processes is the lack of adequate experimental data for simulating the material properties. Moreover, for damage models based on fracture energy, the correct selection of the energy value is critical for the chip formation process. It is usually difficult to obtain the fracture energy values and requires complex tests. In this work, an analysis of the influence of this fracture energy on the cutting force and the chip generation process has been carried out for different sets of cutting parameters. The aim is to present an empirical relationship, that allows selecting the fracture energy based on the cutting force and cutting parameters. The work is based on a FEM model of an orthogonal turning process for Ti6Al4V alloy using Abaqus/Explicit and the fracture energy empirical relation. This work shows that it is necessary to adjust the fracture energy for each combination of cutting conditions, to be able to fit the experimental results. The cutting force and the chip geometry are analyzed, showing how the developed model adapts to the experimental results. It shows that as the cutting speed and the feed increase, the fracture energy value that best adapts to the model decreases. The evolution shows a more pronounced decrease related to the feed increment and high cutting speed.
Highlights
One of the main problems that exists when working with Finite Element Methods (FEM) applied to machining processes is the lack of adequate experimental data for simulating the material properties
Due to the complexity of the material, the existing proposed FEM models are constantly changing based on newly discovered knowledge? Recent articles show that this field of study is still evolving and highlight the mentioned complexity of the material
Some examples can be found in the studies of Chen et al.[11], where different constitutive models such as the Johnson–Cook (JC), the Johnson–Cook Modified (JCM) and the Khane Huange Liang model (KHL) are compared
Summary
One of the main problems that exists when working with Finite Element Methods (FEM) applied to machining processes is the lack of adequate experimental data for simulating the material properties. The numerical models, most of which are based on the Finite Element Method (FEM), usually are presented as a suitable tool to perform a reliable analysis This is essential to improve the quality of the machining processes, from a functional perspective and from an economic point of view[10]. Even though the literature regarding this topic is vast, the simulation models that comprise the constitutive equations, parameters, etc., are constantly changing and improving This helps to obtain results that better adapt to the real behavior of the alloy under study. Childs et al.[13] combined FEM simulation with experimental tests to develop a constitutive equation This combination better describes the flow stress,failure behavior and examines which parameters are critical to obtain good results. Bai et al.[10] have proposed another analytical model for chip formation prediction in orthogonal cutting of Ti6Al4V
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