Investigation of process parameters in orthogonal cutting using finite element approaches.
Investigation of process parameters in orthogonal cutting using finite element approaches.
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DOI：
10.1016/j.heliyon.2020.e05498
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发表时间：
2020-11
期刊：
影响因子：
4
通讯作者：
Abd-Rabou M
中科院分区：
文献类型：
--
作者：
Soliman HA;Shash AY;El Hossainy TM;Abd-Rabou M
采用拉格朗日法和任意拉格朗日欧拉法对AISI 1045钢的正交切削力进行了二维有限元分析。Johnson-Cook（J-C）模型用于定义模拟材料的塑性和失效特性。利用测力计对预测力进行了实验验证。在结果准确性、阅读稳定性和芯片形态方面，模拟方法和实验工作之间进行了比较。此外，本研究采用新的建模思想，通过定义网格单元的近零损伤准则来控制网格单元沿着切屑分离线的过度变形。结果表明，LAG和ALE方法可以预测切削力，但具有不同的精度，LAG和ALE结果偏离实验结果的最小误差百分比分别为3.6%和0.14%。ALE方法在仿真过程中显示出稳定的力读数和连续光滑的切屑，而LAG方法显示出不稳定的力读数和不连续的真实切屑。工业工程;材料科学;机械工程;制造工程机械设计;机械加工正交切削;有限元分析;拉格朗日法;任意拉格朗日-欧拉法;约翰逊-库克模型。
The cutting force in orthogonal cutting of steel AISI 1045 was predicted by applying 2D finite element analysis (FEA) using two methods; (i) Lagrangian (LAG) and (ii) Arbitrary Lagrangian Eulerian (ALE). Johnson-Cook (J-C) models were used for defining plastic and failure properties of simulated materials. The predicted force was validated experimentally by using dynamometer. Comparison held between the simulation methods and experimental work in terms of results accuracy, reading stability, and chip morphology. Furthermore, this study adopted new modeling idea to control the excessive distortion of mesh elements along chip separation line by defining nearly zero damage criterion for these elements. The results demonstrated that LAG and ALE methods could predict the cutting force but with different accuracy, as LAG and ALE results deviated from experimental results with minimum error percentage 3.6% and 0.14% respectively. As well, ALE method showed stable force readings and continues smooth chip during simulation, while LAG method showed unstable force readings and discontinuous realistic chip. Industrial engineering; Materials science; Mechanical engineering; Manufacturing engineering; Machine design; Machining; Orthogonal cutting, Finite element analysis; Lagrangian method, Arbitrary Lagranigan-Eulerian method; Johnson-cook model.
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