FE-simulation of the Cutting Process under Consideration of Cutting Fluid

Klocke, Fritz; Döbbeler, Benjamin; Peng, Bingxiao; Lakner, Thomas

doi:10.1016/j.procir.2017.03.235

Cited by 29 publications

(8 citation statements)

References 7 publications

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“…When comparing with the ALE method, it has been proved that [22,23] the chip morphology and cutting forces from the CEL model were more similar to the experimental one when cutting Ti6Al4V, and avoidance of mesh deformation in the CEL simulation leads to a decrease in computing time. The CEL method has been successfully used in metal cutting simulations by many studies [21,24,25] with promising results as well.…”

Section: Introductionmentioning

confidence: 99%

Numerical contribution to segmented chip effect on residual stress distribution in orthogonal cutting of Inconel718

Liu

Agmell

et al. 2020

Int J Adv Manuf Technol

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Segmented chip morphology has a significant influence on distribution of residual stress and surface topography on machined surface in machining difficult-to-cut materials. In this paper, Coupled Eulerian and Lagrangian (CEL) model is employed to investigate the effect of segmented chip on surface integrity (residual stress distribution and surface topography) in orthogonal machining of Inconel718 with uncoated carbide inserts. A mesh sensitivity study of chip morphology and residual stress distribution is performed by developing the following three different grid resolutions: coarse (mesh size 35 μm), medium (10 μm) and fine (5 μm). Comparing with the experimental results, it is clear that the numerical model presents reasonable results, including the chip morphology, temperature distribution, cutting forces, residual stress profile and surface fluctuation period. As for the generated surface integrity, a waved surface and cyclic residual stress distribution are found with the segmented chip due to the periodical mechanical and thermal loadings acting on the machined surface. Furthermore, the formation of single chip segment is investigated in-depth to explain the residual stress distribution generation.

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Section: Introductionmentioning

confidence: 99%

Numerical contribution to segmented chip effect on residual stress distribution in orthogonal cutting of Inconel718

Liu

Agmell

et al. 2020

Int J Adv Manuf Technol

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“…It consists of both Eulerian and Lagrangian formulations, where typically the workpiece is modelled with Eulerian formulation and the tool is described by a Lagrangian formulation. The CEL formulation has been successfully adopted in metal cutting simulations by [14,15,20,28] with promising results.…”

Section: Introductionmentioning

confidence: 99%

Development of a simulation model to study tool loads in pcBN when machining AISI 316L

Agmell

Bushlya

Laakso

et al. 2018

Int J Adv Manuf Technol

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This paper presents the development of a FE-simulation model to predict the mechanical stresses and thermal loads that a cutting tool of polycrystalline cubic boron nitride (pcBN) is subjected to, when machining AISI 316L. The serrated chip formation of AISI 316L has a major impact on the periodic loads acting on the cutting tool. Therefore, it is vital to correctly model this serrated chip formation. One of the major difficulties with FE-simulations of metal cutting is that the extreme deformations in the workpiece material, often leads to a highly distorted mesh. This paper uses the Coupled EulerianLagrangian (CEL) formulation in Abaqus/Explicit, where the workpiece is modelled with the Eulerian formulation and the cutting tool by the Lagrangian one. This CEL formulation enables to completely avoid mesh distortion. To capture the chip serration process, the workpiece material is described with the Johnson-Cook damage model. The FE-simulation results are validated via comparison of the modelled cutting forces, chip serration frequency, and contact length against experimental ones.

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“…The Coupled Eulerian-Lagrangian (CEL) mesh formulation has been implemented in orthogonal cutting simulations [11], [12], and more recently is being implemented to study chip segmentation [13] and to consider the fluid-structure interaction of the chip with coolant [14].…”

Section: Introductionmentioning

confidence: 99%