Simulation of metal cutting using a physically based plasticity model

Abstract

Metal cutting is one of the most common metal shaping processes. Specified geometrical and surface properties are obtained by break-up of the material removed by the cutting edge into a chip. The chip formation is associated with a large strain, high strain rate and a locally high temperature due to adiabatic heating which make the modelling of cutting processes difficult. This study compares a physically based plasticity model and the Johnson-Cook model. The latter is commonly used for high strain rate applications. Both material models are implemented into the finite element software MSC.Marc and compared with cutting experiments. The deformation behaviour of SANMAC 316L stainless steel during an orthogonal cutting process is studied.

A high temperature nanoindentation study of Al–Cu wrought alloy

“…Additionally, deformation behavior during high rate loads, strain hardening/softening, thermal softening as well as large variations in strain rate and temperatures may deliver promising results in describing machining processes [61].…”

Comparison of multiresolution continuum theory and non-local damage model for use in simulation of manufacturing processes

“…The latter requires special procedures in order to obtain mesh-independent solutions, as standard approaches always concentrate the damage to the smallest element in the softening region. This size effect in the cutting process as described in (Nakayama and Tamura, 1968) is frequently encountered in simulation (Svoboda et al, 2010;Wu et al, 2011). Physical causes of this nonlocal numerical instability can be seen, for example, in the homogenization of microstructural heterogeneity at small scale (Bažant and Jirásek, 2002).…”

Dislocation Density Based Flow Stress Model Applied to the PFEM Simulation of Orthogonal Cutting Processes of Ti-6Al-4V

“…Here, χ is the fraction of mechanical energy spent on vacancy generation, Q v f is the activation energy of vacancy formation, ζ is the neutralization effect by vacancy emiting and absorbing jogs, c j is the concentration of jogs, Ω 0 is the atomic volume, D vm is the diffusivity of vacancies andṪ is the time derivative of the temperature field. The coupled solution of the system of ordinary differential equations (ODE) of Equations (9) and (21) is carried out at elementary level with a Newton-Raphson iterative scheme, a similar solution scheme to coupled equations is presented in References [27,31,32]. The coupled solution of Equations Given the new value ofε p and ε p , and the old value X d , X s , X g , ρ i , g and c v .…”

“…Therefore, it is preferable to use models which are related to the physics of the deformation because the range of validity out of the experimental calibration range is larger compared to phenomenological models. There is evidence of this better behavior when the dislocation density (DD) constitutive model was used to model metal cutting with SANMAC 316L stainless steel in References [27,31,32]. A physically based Voyiadjis-Abed model including the hardening due to dynamic strain aging is presented in References [33,34], it is expected that including the dynamics strain aging in the numerical modeling of metal cutting process will increase the accuracy of the results.…”