基于光滑粒子流体动力学方法与TANH本构方程的钛合金切屑形态预测
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摘要
引入TANH本构方程,建立了钛合金切削过程的光滑粒子流体动力学(SPH)方法的切削模型.新模型解决了基于有限元方法(FEM)的传统切削模型经常出现的网格畸变问题,另外利用控制变量法标定出TANH本构方程的修正系数.相较于传统的Johnson-Cook本构模型,该模型将材料的应变软化现象考虑在内,更加准确描述出钛合金在大应变和动态再结晶情况下材料的动态力学性能.同时,新模型很好解释了钛合金切削过程中锯齿形切屑的形成过程与形成机理.实验结果与模拟结果对比显示,基于SPH方法与TANH本构方程的切屑模型可以准确可靠地预测钛合金切屑形态与切削力.
By implementing a TANH constitutive equation, a cutting model is established with smoothed particle hydrodynamic(SPH) method to simulate the titanium alloy's cutting process. The new model effectively avoids the element distortion problem which always occurs in the traditional cutting model based on the finite element method(FEM). Additionally, the correction parameters of TANH equation are calibrated with control variable method. Compared to the traditional Johnson-Cook constitutive model, the new model takes the strain softening into account, describes the dynamic mechanical properties of the material more accurately under a large strain condition and dynamic recrystallization mechanism. The new model also explains the formation and mechanism of saw-tooth chips very well in the cutting process of titanium alloy. Compared with experimental results, simulation results show the new cutting model predicts the chip morphology and cutting force accurately.
By implementing a TANH constitutive equation, a cutting model is established with smoothed particle hydrodynamic(SPH) method to simulate the titanium alloy's cutting process. The new model effectively avoids the element distortion problem which always occurs in the traditional cutting model based on the finite element method(FEM). Additionally, the correction parameters of TANH equation are calibrated with control variable method. Compared to the traditional Johnson-Cook constitutive model, the new model takes the strain softening into account, describes the dynamic mechanical properties of the material more accurately under a large strain condition and dynamic recrystallization mechanism. The new model also explains the formation and mechanism of saw-tooth chips very well in the cutting process of titanium alloy. Compared with experimental results, simulation results show the new cutting model predicts the chip morphology and cutting force accurately.
引文
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[10] CHEN R,SHAO S,LIU X,et al.Applications of shallow water SPH model in mountainous rivers[J].Journal of Applied Fluid Mechanics,2015,8(4):863-870.
[11] BOUSCASSE B,COLAGROSSI A,MARRONE S,et al.SPH modelling of viscous flow past a circular cylinder interacting with a free surface[J].Computers & Fluids,2017,146:190-212.
[12] FERRAND M,JOLY A,KASSIOTIS C,et al.Unsteady open boundaries for SPH using semi-analytical conditions and Riemann solver in 2D[J].Computer Physics Communications,2017,210:29-44.
[13] DONG X W,LIU G R,LI Z L,et al.A smoothed particle hydrodynamics (SPH) model for simulating surface erosion by impacts of foreign particles [J].Tribology International,2016,95:267-278.
[14] JOHNSON G R,COOK W H.A constitutive model and data for metals subjected to large strains,high strain rates and high temperatures[C]//7th International Symposium on Ballistics.The Hague,Netherlands:International Ballistics Committe,1983:541-547.
[15] JOHNSON G R,COOK W H.Fracture characteristics of three metals subjected to various strains,strain rates,temperatures and pressures [J].Engineering Fracture Mechanics,1985,21(1):31-48.
[16] NIU W L,MO R,LIU G R,et al.Modeling of orthogonal cutting process of A2024-T351 with an improved SPH method[J].International Journal of Advanced Manufacturing Technology,2018,95(1/2/3/4):905-919.
[17] CALAMAZ M,COUPARD D,GIROT F.Numerical simulation of titanium alloy dry machining with a strain softening constitutive law[J].Machining Science and Technology,2010,14(2):244-257.
[18] DUCOBU F,RIVIèRE-LORPHèVRE E,FILIPPI E.Numerical contribution to the comprehension of saw-toothed Ti6Al4V chip formation in orthogonal cutting [J].International Journal of Mechanical Sciences,2014,81:77-87.
[19] YAICH M,AYED Y,BOUAZIZ Z,et al.Numerical analysis of constitutive coefficients effects on FE simulation of the 2D orthogonal cutting process:Application to the Ti6Al4V[J].International Journal of Advanced Manufacturing Technology,2017,93(1/2/3/4):283-303.
[20] HE L J,SU H H,XU J H,et al.Simulation analysis of the influence of dynamic flow stress behavior on chip formation[J].International Journal of Advanced Manufacturing Technology,2018,95(5/6/7/8):2301-2313.
[2] SU G S,LIU Z Q.An experimental study on influences of material brittleness on chip morphology [J].International Journal of Advanced Manufacturing Technology,2010,51(1/2/3/4):87-92.
[3] ZHANG X P,SHIVPURI R,SRIVASTAVA A K.A new microstructure-sensitive flow stress model for the high-speed machining of titanium alloy Ti-6Al-4V [J].Journal of Manufacturing Science and Engineering,2017,139(5):051006.
[4] CHEN G,REN C Z,YANG X Y,et al.Finite element simulation of high-speed machining of titanium alloy (Ti-6Al-4V) based on ductile failure model [J].International Journal of Advanced Manufacturing Technology,2011,56(9/10/11/12):1027-1038.
[5] LIU G R,LIU M B.光滑流体动力学——一种无网格粒子法[M].韩旭,杨刚,强洪夫,译.长沙:湖南大学出版社,2005.LIU G R,LIU M B.Smoothed particle hydrodyna-mics:A meshfree particle method[M].HAN Xu,YANG Gang,QIANG Hongfu,trans.Changsha:Hunan University Press,2005.
[6] LUCY L B.A numerical approach to the testing of the fission hypothesis [J].Astronomical Journal,1977,82(12):1013-1024.
[7] YANG X F,DAI L,KONG S C.Simulation of liquid drop impact on dry and wet surfaces using SPH me-thod [J].Proceedings of the Combustion Institute,2017,36(2):2393-2399.
[8] 强洪夫,范树佳,陈福振,等.基于拟流体模型的SPH新方法及其在弹丸超高速碰撞薄板中的应用[J].爆炸与冲击,2017,37(6):990-1000.QIANG Hongfu,FAN Shujia,CHEN Fuzhen,et al.A new smoothed particle hydrodynamics method based on the pseudo-fluid model and its application in hyperrelocity impact of a projectile on a thin plate[J].Explosion and Shock Waves,2017,37(6):990-1000.
[9] 欧阳义平,杨启.SPH法数值仿真三维切削破岩和切削力估算[J].上海交通大学学报,2016,50(1):84-90.OUYANG Yiping,YANG Qi.Numerical simulation of rock cutting in 3D with SPH method and estimation of cutting force[J].Journal of Shanghai Jiao Tong University,2016,50(1):84-90.
[10] CHEN R,SHAO S,LIU X,et al.Applications of shallow water SPH model in mountainous rivers[J].Journal of Applied Fluid Mechanics,2015,8(4):863-870.
[11] BOUSCASSE B,COLAGROSSI A,MARRONE S,et al.SPH modelling of viscous flow past a circular cylinder interacting with a free surface[J].Computers & Fluids,2017,146:190-212.
[12] FERRAND M,JOLY A,KASSIOTIS C,et al.Unsteady open boundaries for SPH using semi-analytical conditions and Riemann solver in 2D[J].Computer Physics Communications,2017,210:29-44.
[13] DONG X W,LIU G R,LI Z L,et al.A smoothed particle hydrodynamics (SPH) model for simulating surface erosion by impacts of foreign particles [J].Tribology International,2016,95:267-278.
[14] JOHNSON G R,COOK W H.A constitutive model and data for metals subjected to large strains,high strain rates and high temperatures[C]//7th International Symposium on Ballistics.The Hague,Netherlands:International Ballistics Committe,1983:541-547.
[15] JOHNSON G R,COOK W H.Fracture characteristics of three metals subjected to various strains,strain rates,temperatures and pressures [J].Engineering Fracture Mechanics,1985,21(1):31-48.
[16] NIU W L,MO R,LIU G R,et al.Modeling of orthogonal cutting process of A2024-T351 with an improved SPH method[J].International Journal of Advanced Manufacturing Technology,2018,95(1/2/3/4):905-919.
[17] CALAMAZ M,COUPARD D,GIROT F.Numerical simulation of titanium alloy dry machining with a strain softening constitutive law[J].Machining Science and Technology,2010,14(2):244-257.
[18] DUCOBU F,RIVIèRE-LORPHèVRE E,FILIPPI E.Numerical contribution to the comprehension of saw-toothed Ti6Al4V chip formation in orthogonal cutting [J].International Journal of Mechanical Sciences,2014,81:77-87.
[19] YAICH M,AYED Y,BOUAZIZ Z,et al.Numerical analysis of constitutive coefficients effects on FE simulation of the 2D orthogonal cutting process:Application to the Ti6Al4V[J].International Journal of Advanced Manufacturing Technology,2017,93(1/2/3/4):283-303.
[20] HE L J,SU H H,XU J H,et al.Simulation analysis of the influence of dynamic flow stress behavior on chip formation[J].International Journal of Advanced Manufacturing Technology,2018,95(5/6/7/8):2301-2313.
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