Abstract
AbstractParameters in a complex material model for powder compaction, based on a continuum mechanics approach, are evaluated using real insert geometries. The parameter sensitivity with respect to density and stress after compaction, pertinent to a wide range of geometries, is studied in order to investigate completeness and limitations of the material model. Finite element simulations with varied material parameters are used to build surrogate models for the sensitivity study. The conclusion from this analysis is that a simplification of the material model is relevant, especially for simple insert geometries. Parameters linked to anisotropy and the plastic strain evolution angle have a small impact on the final result.
Highlights
Classic cutting inserts are manufactured by compacting hard metal powder blends into a predefined shape followed by sintering to full density and posttreatment
The first type can be described as a micromechanical approach using analytical (Ref 2) or numerical methods, such as the discrete element method (DEM) (Ref 3-5)
Previous research presented in (Ref 12) on inverse modeling with an instrumented die (Ref 13), where the force against a die wall and press forces was compared with FEsimulations, shows that either a less complex material model or more extensive tests, or a combination of both, are needed to complete a full material description including characterization
Summary
Classic cutting inserts are manufactured by compacting hard metal powder blends into a predefined shape followed by sintering to full density and posttreatment. Previous research presented in (Ref 12) on inverse modeling with an instrumented die (Ref 13), where the force against a die wall and press forces was compared with FEsimulations, shows that either a less complex material model or more extensive tests, or a combination of both, are needed to complete a full material description including characterization. To better understand which parameters of the material model (Ref 11) could be possibly disregarded and to suggest further material characterization tests, sensitivity studies are presently performed To some extent, this is performed in (Ref 14), but there is a need to do this for different kinds of stress fields, i.e., more inserts, and recording responses over the whole cutting insert. The response variables are density and stress, after compaction or at maximum compaction, at [10–20] points over the whole geometry
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