Some insights on the modelling of chip formation and its morphology during metal cutting operations

Mabrouki, Tarek; Courbon, C.; Zhang, Yancheng; Rech, Joël; Nélias, Daniel; Asad, Muhammad; Hamdi, Hédi; Belhadi, Salim; Salvatore, Ferdinando

doi:10.1016/j.crme.2016.02.003

Cited by 60 publications

(34 citation statements)

References 42 publications

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“…Especially, Rice and Tracey's expression became very popular in the fracture application and various researchers extended or modified the model to study the damage evolution. Johnson and Cook [28] extended this expression by considering separately the strain rate sensitivity and temperature dependency, which allowed a broad application of this model in a wide array of thermomechanical processes [5,8] . However, the work of Wierzbicki et al [29] proved that the approximation of the failure strain with a monotonically decreasing function of stress triaxiality is poor, while a strong dependency to the third stress invariant is to be preferred.…”

Section: Introductionmentioning

confidence: 99%

Numerical and experimental investigations of Ti-6Al-4V chip generation and thermo-mechanical couplings in orthogonal cutting

Harzallah

Pottier

Senatore

et al. 2017

International Journal of Mechanical Sciences

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a b s t r a c tThe chip formation mechanism of the Ti-6Al-4V remains a challenging problem in the machining process as well as its modeling and simulation. Starting from experimental observation on the titanium alloys Ti-6Al-4V machining shows that the ductile fracture in the chip formation is dominated by the shear phenomenon under high strain rate and temperature, the present work develops a new coupled behavior and damage model for better representation and understanding of the chip formation process. The behavior and damage of Ti-6Al-4V have been studied via hat-shaped specimen under temperature up to 900 °C and strain rate up to 1000 s − 1 . An inverse identification method based on Finite Element (FE) is established in order to determine the constitutive law's parameters. The prediction of the segmented chip was analyzed through 3D finite element orthogonal cutting model which was validated by an in-situ and post-mortem orthogonal cutting machining observations. Finally, a particular attention is focused on the chip formation genesis which is described by three steps: Growth, Germination and Extraction.

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Section: Introductionmentioning

confidence: 99%

Numerical and experimental investigations of Ti-6Al-4V chip generation and thermo-mechanical couplings in orthogonal cutting

Harzallah

Pottier

Senatore

et al. 2017

International Journal of Mechanical Sciences

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“…Umer et al studied chip morphology predictions while machining hardened tool steel using finite element and smoothed particles hydrodynamics methods [32]. The topic of chip morphology and its formation modeling during metal cutting operations was also the subject of a study by Mabrouki et al [33].…”

Section: State Of the Artmentioning

confidence: 99%

“…Metals 2019, 9, x FOR PEER REVIEW 4 of 26 hydrodynamics methods [32]. The topic of chip morphology and its formation modeling during metal cutting operations was also the subject of a study by Mabrouki et al [33]. In chip machining, the chip forming process is often accompanied by the formation of a built-up edge (BUE) in the face of the tool and it is necessary to take this phenomenon into account.…”

Section: State Of the Artmentioning

confidence: 99%

Research on Chip Shear Angle and Built-Up Edge of Slow-Rate Machining EN C45 and EN 16MnCr5 Steels

Monková

Monka

Sekerakova

et al. 2019

Metals

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One of the phenomena that accompanies metal cutting is extensive plastic deformation and fracture. The excess material is plastically deformed, fractured, and removed from the workpiece in the form of chips, the formation of which depends on the type of crack and their propagation. Even in case of the so-called 'continuous' chip formation there still has to be a fracture, as the cutting process involves the separation of a chip from the workpiece. Controlling the chip separation and its patterning in a suitable form is the most important problem of the current industrial processes, which should be highly automated to achieve maximal production efficiency. The article deals with the chip root evaluation of two EN C45 and EN 16MnCr5 steels, focusing on the shear angle measuring and built-up edge observation as important factors influencing the machining process, because a repeated formation and dislodgement of built-up edge unfavorably affects changes in the rake angle, causing fluctuation in cutting forces, and thus inducing vibration, which is harmful to the cutting tool. Consequently, this leads to surface finish deterioration. The planing was selected as a slow-rate machining operation, within which orthogonal and oblique cutting has been used for the comparative chips' root study. The planned experiment was implemented at three levels (lower, basic, and upper) for the test preparation and the statistical method, and regression function was used for the data evaluation. The mutual connections among the four considered factors (cutting speed, cutting depth, tool cutting edge inclination, and rake angle) and investigated by the shear angle were plotted in the form of graphical dependencies. Finally, chips obtained from both steels types and within both cutting methods were systematically processed from the microscopic (chip root) and macroscopic (chip pattern) points of view.Metals 2019, 9, 956 2 of 27 of a machined surface are in many cases not achievable by mechanical working or casting processes, because the surfaces of the parts are adversely affected. This is why machining is needed.[3] Controlling the chip separation and its patterning in a suitable form is the most important problem of the current industrial processes, which should be highly automated to achieve maximal production efficiency.One of the phenomena that accompanies metal cutting is extensive plastic deformation and fracture. The excess material is plastically deformed, fractured, and removed from the workpiece in the form of chips, the formation of which depends on the type of crack and their propagation. Even in the case of so-called 'continuous' chip formation there still has to be a fracture, as the cutting process involves the separation of a chip from the workpiece. Chips at the machining are formed due to tearing and shearing, the workpiece material adjacent to the tool face is compressed and a crack runs ahead of the cutting tool and towards the body of the workpiece. Cutting takes place intermittently and there is no movement of the w...

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“…They analysed various chip shapes by using different plastic displacement values and found that chip transition occurs from continuous to segmentation with increasing feeds. Mabrouki et al [2] investigated the characteristics of chip morphology and chip microstructures during cutting operation under high loading. Mabrouki et al [18] also investigated the dry cutting of an aeronautic aluminium alloy and developed the numerical model based on the Johnson-Cook law incorporating with material damage evolution by using a fracture energy model.…”

Section: Chip Formation Mechanism Using Finite Element Simulationmentioning

confidence: 99%

“…The continuous chip is often considered to be an ideal chip that generates stable cutting forces; however, it is not desired for automated machining because the continuous chips may obstruct the machining process, which may lead to unpredictable damage on the machined surface, cutting tool or machine tool. To minimize these problems, serrated chips that are easier to break and remove are preferred during machining [1] and [2], so, predicting the cutting conditions which lead to a serrated chip has become increasingly important.…”

Section: Introductionmentioning

confidence: 99%

Chip Formation Mechanism Using Finite Element Simulation

Öpöz¹,

Chen²

2016

SV-JME

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Opoz, TT and Chen, X Chip formation mechanism using finite element simulation http://researchonline.ljmu.ac.uk/4059/ Article LJMU has developed LJMU Research Online for users to access the research output of the University more effectively. Copyright © and Moral Rights for the papers on this site are retained by the individual authors and/or other copyright owners. Users may download and/or print one copy of any article(s) in LJMU Research Online to facilitate their private study or for non-commercial research. You may not engage in further distribution of the material or use it for any profit-making activities or any commercial gain.The version presented here may differ from the published version or from the version of the record. Please see the repository URL above for details on accessing the published version and note that access may require a subscription. INTRODUCTIONChip formation during machining processes is a material removal process in which the materials are removed from the workpiece in the form of numerous tiny chips. To understand chip formation regarding the chip types, shapes as well as the stress/strain distribution would help the prediction of cutting force and thermal behaviour to avoid unexpected vibration and thermal damage. To do this, the finite element models of machining processes are very popular for simulating chip formation [1] to [15]. The reason is to minimize labour cost and save time by reducing expensive experimental tests. In contrast, the estimation of some physical phenomena such as the distribution of stress and strain under machining conditions is quite difficult to accomplish with experimental tests. Finite element method (FEM) provides a convenient method to visualise material performance under different machining conditions. Therefore, the prediction of chip types and chip shapes under different operating conditions is one of the significant benefits provided by FEM simulations. In metal cutting processes, often three types of chip formation occur (continuous chips, serrated chips, and discontinuous chips), which are produced as a result of the cutting deformation mechanism, operating parameters, and workpiece mechanical and thermal properties. The continuous chip is often considered to be an ideal chip that generates stable cutting forces; however, it is not desired for automated machining because the continuous chips may obstruct the machining process, which may lead to unpredictable damage on the machined surface, cutting tool or machine tool. To minimize these problems, serrated chips that are easier to break and remove are preferred during machining [1] and [2], so, predicting the cutting conditions which lead to a serrated chip has become increasingly important.In some literature, serrated chips are called sawtooth shape or continuous segmented chips. Increased segmentation on continuous chips eventually leads to serrated chips. It is common knowledge that segmentation during chip formation is triggered by two phenomena: the formation of the adiabatic shear band a...

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Some insights on the modelling of chip formation and its morphology during metal cutting operations

Abstract: International audienc

Cited by 60 publications

References 42 publications

Numerical and experimental investigations of Ti-6Al-4V chip generation and thermo-mechanical couplings in orthogonal cutting

Numerical and experimental investigations of Ti-6Al-4V chip generation and thermo-mechanical couplings in orthogonal cutting

Research on Chip Shear Angle and Built-Up Edge of Slow-Rate Machining EN C45 and EN 16MnCr5 Steels

Chip Formation Mechanism Using Finite Element Simulation

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