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CLC number: TG58

On-line Access: 2016-11-03

Received: 2016-01-18

Revision Accepted: 2016-06-17

Crosschecked: 2016-10-13

Cited: 0

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Citations:  Bibtex RefMan EndNote GB/T7714

 ORCID:

Usama Umer

http://orcid.org/0000-0001-8715-7905

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Journal of Zhejiang University SCIENCE A 2016 Vol.17 No.11 P.873-885

http://doi.org/10.1631/jzus.A1600023


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


Author(s):  Usama Umer, Jaber Abu Qudeiri, Mohammad Ashfaq, Abdulrahman Al-Ahmari

Affiliation(s):  Princess Fatima Alnijiris’s Research Chair for Advanced Manufacturing Technology (FARCAMT), Advanced Manufacturing Institute, King Saud University, Riyadh, Saudi Arabia; more

Corresponding email(s):   usamaumer@yahoo.com

Key Words:  Chip morphology, Finite element (FE), Smoothed particles hydrodynamics (SPH), Hardened tool steel, Serrated chips


Usama Umer, Jaber Abu Qudeiri, Mohammad Ashfaq, Abdulrahman Al-Ahmari. Chip morphology predictions while machining hardened tool steel using finite element and smoothed particles hydrodynamics methods[J]. Journal of Zhejiang University Science A, 2016, 17(11): 873-885.

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%T Chip morphology predictions while machining hardened tool steel using finite element and smoothed particles hydrodynamics methods
%A Usama Umer
%A Jaber Abu Qudeiri
%A Mohammad Ashfaq
%A Abdulrahman Al-Ahmari
%J Journal of Zhejiang University SCIENCE A
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%I Zhejiang University Press & Springer
%DOI 10.1631/jzus.A1600023

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T1 - Chip morphology predictions while machining hardened tool steel using finite element and smoothed particles hydrodynamics methods
A1 - Usama Umer
A1 - Jaber Abu Qudeiri
A1 - Mohammad Ashfaq
A1 - Abdulrahman Al-Ahmari
J0 - Journal of Zhejiang University Science A
VL - 17
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PB - Zhejiang University Press & Springer
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DOI - 10.1631/jzus.A1600023


Abstract: 
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 () 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.

基于有限元和光滑粒子流体动力学的硬质工具钢切屑形貌预测方法研究

目的:获得有效的高精度切屑形貌仿真方法。
创新点:通过比较不同切削参数下采用光滑粒子流体动力学模型和有限元模型仿真获得的切屑形貌,证明光滑粒子流体动力学模型可以很好地实现对节状切屑的仿真,而不需要额外的几何或基于网格的切屑分离准则。
方法:基于有限元和光滑粒子流体动力学的切削形貌仿真方法。
结论:通过比较不同切削参数下采用光滑粒子流体动力学模型和有限元模型仿真获得的切屑形貌,证明了基于裂纹形成与扩展理论,采用合理疲劳参数的标准Johnson-Cook模型完全可以实现对节状切屑形成过程的仿真,也即无需采用修正的Johnson-Cook模型。同时证明了有限元模型和光滑粒子流体动力学方法均可满足不同切削速度和进给量条件下的切削力和切屑形貌仿真。

关键词:切屑形貌;有限元;光滑粒子流体动力学;淬硬工具钢;锯齿形切屑

Darkslateblue:Affiliate; Royal Blue:Author; Turquoise:Article

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