Present Situation and Future Trends in Modelling of Machining Operations Progress Report of the CIRP Working Group ‘Modelling of Machining Operations’

Prediction of chip morphology and segmentation during the machining of titanium alloys

This paper presents a methodology to determine simultaneously (a) the flow stress at high deformation rates and temperatures that are encountered in the cutting zone, and (b) the friction at the chip–tool interface. This information is necessary to simulate high-speed machining using FEM based programs. A flow stress model based on process dependent parameters such as strain, strain-rate and temperature was used together with a friction model based on shear flow stress of the workpiece at the chip–tool interface. High-speed cutting experiments and process simulations were utilized to determine the unknown parameters in flow stress and friction models. This technique was applied to obtain flow stress for P20 mold steel at hardness of 30 HRC and friction data when using uncoated carbide tooling at high-speed cutting conditions. The average strain, strain-rates and temperatures were computed both in primary (shear plane) and secondary (chip–tool contact) deformation zones. The friction conditions in sticking and sliding regions at the chip–tool interface are estimated using Zorev's stress distribution model. The shear flow stress ( k chip ) was also determined using computed average strain, strain-rate, and temperatures in secondary deformation zone, while the friction coefficient ( μ ) was estimated by minimizing the difference between predicted and measured thrust forces. By matching the measured values of the cutting forces with the predicted results from FEM simulations, an expression for workpiece flow stress and the unknown friction parameters at the chip–tool contact were determined.

Determination of workpiece flow stress and friction at the chip-tool contact for high-speed cutting

Finite element analysis of the effect of sequential cuts and tool-chip friction on residual stresses in a machined layer

Finite element models of orthogonal cutting with application to single point diamond turning

Process Modeling of Orthogonal Cutting by the Rigid-Plastic Finite Element Method

Finite element method for rigid-plastic analysis of metal forming—Formulation for finite deformation

Simulation of plane-strain rolling by the rigid-plastic finite element method

Simulation of three-dimensional deformation in rolling by the finite-element method

A Method of Determining Flow Stress under Forming Conditions

K. Osakada

Papers

Process Modeling of Orthogonal Cutting by the Rigid-Plastic Finite Element Method

Finite element method for rigid-plastic analysis of metal forming—Formulation for finite deformation

Simulation of plane-strain rolling by the rigid-plastic finite element method

Simulation of three-dimensional deformation in rolling by the finite-element method

A Method of Determining Flow Stress under Forming Conditions