Chip morphology predictions while machining hardened tool steel using finite element and smoothed particles hydrodynamics methods

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• 作者：Usama Umer ; Jaber Abu Qudeiri ; Mohammad Ashfaq…
• 关键词：Chip morphology ; Finite element (FE) ; Smoothed particles hydrodynamics (SPH) ; Hardened tool steel ; Serrated chips
• 刊名：Journal of Zhejiang University-SCIENCE A
• 出版年：2016
• 出版时间：November 2016
• 年：2016
• 卷：17
• 期：11
• 页码：873-885
• 全文大小：
• 刊物类别：Engineering
• 刊物主题：Mechanical Engineering; Civil Engineering; Classical and Continuum Physics; Industrial Chemistry/Chemical Engineering;
• 出版者：Zhejiang University Press
• ISSN：1862-1775
• 卷排序：17

文摘

Chip morphology predictions in metal cutting have always been challenging because of the complexity of the various multiphysical phenomena that occur across the tool-chip interface. An accurate prediction of chip morphology is a key factor in the assessment of a particular machining operation with regard to both tool performance and workpiece quality. Although finite element (FE) models are being developed over the last two decades, their capabilities in modeling correct material flow around the tool tip with shear localization are very limited. FE models with an arbitrary Lagrangian Eulerian (ALE) approach are able to simulate correct material flow around the tool tip. However, these models are unable to predict any shear localization based on material flow criteria. On the other hand, FE models with a Lagrangian formulation can simulate shear localization in the chip segments; they need to make use of a mesh-based chip separation criterion that significantly affects material flow around the tool tip. In this study a mesh-free method viz. smoothed particles hydrodynamics (SPH) is implemented to simulate shear localization in the chip while machining hardened steel. Unlike other SPH models developed by some researchers, this model is based on a renormalized formulation that can consider frictional stresses along the tool-chip interface giving a realistic chip shape and material flow. SPH models with different cutting parameters are compared with the traditional FE models and it has been found that the SPH models are good for predicting shear localized chips and do not need any geometric or mesh-based chip separation criteria.