A Numerical-Experimental Study on Orthogonal Cutting of AISI 1045 Steel and Ti6Al4V Alloy: SPH and FEM Modeling with Newly Identified Friction Coefficients

Afrasiabi, Mohamadreza; Saelzer, Jannis; Berger, Sebastian; Iovkov, Ivan; Klippel, Hagen; Röthlin, Matthias; Zabel, Andreas; Biermann, Dirk; Wegener, Konrad

doi:10.3390/met11111683

Cited by 26 publications

(17 citation statements)

References 58 publications

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“…The SPH method shows the same tendencies concerning cutting force and stress evolution but presents more discrepancies with the experimental data, mainly on cutting force values and chip morphology. Nevertheless, the material flow seems to be more realistic around the cutting edge than in the FE model [ 19 ].…”

Section: Resultsmentioning

confidence: 99%

Study of the Influence of Cutting Edge on Micro Cutting of Hardened Steel Using FE and SPH Modeling

et al. 2022

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Micromachining allows the production of micro-components with complex geometries in various materials. However, it presents several scientific issues due to scale reduction compared to conventional machining. These issues are called size effects. At this level, micromachining experiments raise technical difficulties and significant costs. In this context, numerical modeling is widely used in order to study these different size effects. This article presents four different numerical models of micro-cutting of hardened steel, a Smooth Particle Hydrodynamics (SPH) model and three finite element (FE) models using three different formulations: Lagrangian, Arbitrary Eulerian–Lagrangian (ALE) and Coupled Eulerian–Lagrangian (CEL). The objective is to study the effect of tool edge radius on the micro-cutting process through the evolution of cutting forces, chip morphology and stress distribution in different areas and to compare the relevance of the different models. First, results obtained from two models using FE (Lagrangian) and SPH method were compared with experimental data obtained in previous work. It shows that the different numerical methods are relevant for studying geometrical size effects because cutting force and stress distribution correlate with experimental data. However, they present limits due to the calculation approaches. For a second time, this paper presents a comparison between the four different numerical models cited previously in order to choose which method of modeling can present the micro-cutting process.

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Section: Resultsmentioning

confidence: 99%

Study of the Influence of Cutting Edge on Micro Cutting of Hardened Steel Using FE and SPH Modeling

et al. 2022

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“…Saelzer et al [124] and Afrasiabi et al [125] used a commercially available FO IRT to measure the temperature of the rake face during orthogonal cutting to investigate the effect of different tool surfaces on the machining temperature. The fibre was positioned perpendicularly to the tool's rake face.…”

Section: Fibre-optic Infrared Thermometersmentioning

confidence: 99%

A Comparative Review of Thermocouple and Infrared Radiation Temperature Measurement Methods during the Machining of Metals

Leonidas

Ayvar-Soberanis

Laalej

et al. 2022

Sensors

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During the machining process, substantial thermal loads are generated due to tribological factors and plastic deformation. The increase in temperature during the cutting process can lead to accelerated tool wear, reducing the tool’s lifespan; the degradation of machining accuracy in the form of dimensional inaccuracies; and thermally induced defects affecting the metallurgical properties of the machined component. These effects can lead to a significant increase in operational costs and waste which deviate from the sustainability goals of Industry 4.0. Temperature is an important machining response; however, it is one of the most difficult factors to monitor, especially in high-speed machining applications such as drilling and milling, because of the high rotational speeds of the cutting tool and the aggressive machining environments. In this article, thermocouple and infrared radiation temperature measurement methods used by researchers to monitor temperature during turning, drilling and milling operations are reviewed. The major merits and limitations of each temperature measurement methodology are discussed and evaluated. Thermocouples offer a relatively inexpensive solution; however, they are prone to calibration drifts and their response times are insufficient to capture rapid temperature changes in high-speed operations. Fibre optic infrared thermometers have very fast response times; however, they can be relatively expensive and require a more robust implementation. It was found that no one temperature measurement methodology is ideal for all machining operations. The most suitable temperature measurement method can be selected by individual researchers based upon their experimental requirements using critical criteria, which include the expected temperature range, the sensor sensitivity to noise, responsiveness and cost.

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“…The second challenge is in continuous development because as the new materials appear, new constitutive models need to be developed; even so, physically based and dislocation density models have been developed that improve the prediction of the cutting forces in comparison with the Johnson–Cook constitutive model [ 5 , 8 , 9 , 10 ]. The last challenge appears to be less studied than the others in the numerical simulation of cutting, even though the use of better models for describing the friction behavior in metal cutting has been repeatedly concluded by many researchers in the field [ 11 , 12 , 13 , 14 ]. The contribution of this paper is thus directed mainly towards the third challenge in orthogonal cutting modeling.…”

Section: Introductionmentioning

confidence: 99%

“…Although previous studies have demonstrated the capability of PFEM in simulating metal cutting processes, none of them account for temperature-dependent friction coefficients. In the present work, we fill this gap by presenting a PFEM-based orthogonal cutting simulation framework featuring a temperature-dependent friction model with the coefficient values identified in [ 11 ]. The prediction accuracy of PFEM are then compared with the SPH simulation results and experimental measurements taken from the literature.…”

Section: Introductionmentioning

confidence: 99%

Thermomechanical Simulation of Orthogonal Metal Cutting with PFEM and SPH Using a Temperature-Dependent Friction Coefficient: A Comparative Study

2023

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In this work, we apply the Particle Finite Element Method (PFEM) and Smoothed Particle Hydrodynamics (SPH) to simulate the orthogonal cutting chip formation of two workpiece materials, i.e., AISI 1045 steel and Ti6Al4V titanium alloy. A modified Johnson–Cook constitutive model is used to model the plastic behavior of the two workpiece materials. No damage or strain softening is included in the model. The friction between the workpiece and the tool is modeled following Coulomb’s law with a temperature-dependent coefficient. The accuracy of PFEM and SPH in predicting thermomechanical loads at various cutting speeds and depths against the experimental data are compared. The results show that both numerical methods can predict the rake face temperature of AISI 1045 with errors less than 34%. For Ti6Al4V, however, the temperature prediction errors are significantly higher than those of the steel alloy. Errors in force prediction were in the range of 10% to 76% for both methods, which compare very well with those reported in the literature. This investigation infers that the Ti6Al4V behavior under machining conditions is difficult to model on the cutting scale irrespective of the choice of numerical method.

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A Numerical-Experimental Study on Orthogonal Cutting of AISI 1045 Steel and Ti6Al4V Alloy: SPH and FEM Modeling with Newly Identified Friction Coefficients

Cited by 26 publications

References 58 publications

Study of the Influence of Cutting Edge on Micro Cutting of Hardened Steel Using FE and SPH Modeling

Study of the Influence of Cutting Edge on Micro Cutting of Hardened Steel Using FE and SPH Modeling

A Comparative Review of Thermocouple and Infrared Radiation Temperature Measurement Methods during the Machining of Metals

Thermomechanical Simulation of Orthogonal Metal Cutting with PFEM and SPH Using a Temperature-Dependent Friction Coefficient: A Comparative Study

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