Using Nonlinear Contact Mechanics in Process of Tool Edge Movement on Deformable Body to Analysis of Cutting and Sliding Burnishing Processes

Abstract

Properties of the surface layer after cutting or sliding burnishing depend mainly on type of process and its performance conditions. For its comprehensive analysis is necessary to develop an adequate mathematical model and numerical methods of solving it. A common feature of both processes is moving the tool edge on elastic/visco-plastic workpiece. However, these processes are different i.e. the chip formation or chipless forming, therefore, different properties of surface layer depend mainly on: the geometry of the tool edge and its workpiece relative and depth of process. Therefore, this article is about the application of an incremental modelling and numerical solution of the contact problem between movable rigid and elastic/visco-plastic bodies developed in [ to the numerical simulation of physical process of moving a rigid tool on the workpiece.

Application of the FEM Method to Modeling and Analysis of the Cold Thread Rolling Process—Part 1: Conditions for Ensuring a Plane State of Deformations

“…As a result, for successive discrete moments of time τ 0, Δt, 2Δt, … the geometry of the body and the states of incremental displacements, displacement velocities, accelerations, strains, strain rates, and stresses are determined. The concept of incremental description has already been verified by the author and was used to describe other plastic-forming processes: cutting [36][37][38][39][40][41][42], thread rolling [15][16][17]28,29], burnishing rolling [43][44][45][46][47][48][49], drawing [50][51][52], grinding with a single abrasive grain [53], calculating the fatigue strength of products [54][55][56], and diamond sliding burnishing [56].…”

“…The model, according to formula (36), does not require the calculation of material hardening modules at each incremental step, as in the case of the Cowper-Symonds model, because the influence of hardening is already included in the values of true strain. The material parameters in the visco-plastic yield stress model (9) were determined on the basis of the results of experimental tests and it was proven that they have a significant impact on the accuracy of the simulation.…”

“…In an analogous way, as with model (36), the values of the constants in the Cowper-Symonds model (27) were calculated and the following final form was obtained:…”

Experimental and Numerical Investigations and Optimisation of Grain-Oriented Silicon Steel Mechanical Cutting Process

“…The result is a discrete, incremental mathematical model of the physical model. The numerical model uses the updated Lagrange description, which was used to describe nonlinear phenomena on a typical incremental step in the cutting process [24,25]. The task of the incremental analysis is to formulate the geometry of the material being cut, as well as the existing state of increase in displacement, velocity, acceleration, deformation, stress, strain, velocity, etc.…”

Modelling and analysis of the technological processes using finite element method

“…At Department of Technical Mechanics at the Faculty of Mechanical Engineering of the Koszalin University of Technology were developed applications on the system ANSYS (APDL language), which allow a comprehensive time analysis for deformation (displacement, velocity, strain, strain rate), stresses and boundary condition in contact zone tool-object occurring in the object, both the spatial conditions as well as plane, in the processes technological precision machining parts ( Fig. 1): cutting processes [8,36,37,38,45,47,55,56,62,63,66,74], turning processes [20,34,57,75], burnishing rolling processes [1, 2, 3, 6, 7, 11, 17, 22, 28, 29 ,31-33, 36, 46, 49, 51, 60, 61, 65, 71, 73, 76-78], sliding burnishing [43,53,57,58,68], cutting by an abrasive single grain [12,14,19,21,24,25,33,39,40,72], embossing [12,23,30,50,70], thread rolling [1,2,4,5,9,10,…”