Abstract
This paper presents the development of a FE-simulation model to predict the mechanical stresses and thermal loads that a cutting tool of polycrystalline cubic boron nitride (pcBN) is subjected to, when machining AISI 316L. The serrated chip formation of AISI 316L has a major impact on the periodic loads acting on the cutting tool. Therefore, it is vital to correctly model this serrated chip formation. One of the major difficulties with FE-simulations of metal cutting is that the extreme deformations in the workpiece material, often leads to a highly distorted mesh. This paper uses the Coupled Eulerian-Lagrangian (CEL) formulation in Abaqus/Explicit, where the workpiece is modelled with the Eulerian formulation and the cutting tool by the Lagrangian one. This CEL formulation enables to completely avoid mesh distortion. To capture the chip serration process, the workpiece material is described with the Johnson-Cook damage model. The FE-simulation results are validated via comparison of the modelled cutting forces, chip serration frequency, and contact length against experimental ones.
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Abbreviations
- Symbol :
-
Description (Unit)
- A :
-
Initial yield stress in Johnson-Cook (N/mm2)
- A c l :
-
Axial force acting on the clearance face (N)
- A r :
-
Axial force acting on the rake face (N)
- b :
-
Chip width (mm)
- B :
-
Strain hardening modulus in Johnson-Cook (N/mm2)
- C :
-
Strain-rate dependence coefficient in Johnson-Cook
- C p,w :
-
Specific heat capacity of the workpiece material (J/(kg⋅K))
- C p,t :
-
Specific heat capacity of the tool material (J/(kg⋅K))
- C r :
-
Cutting resistance (N/mm2)
- D :
-
Scalar stiffness degradation
- D 1 − 5 :
-
Constants in the Johnson-Cook damage model
- E w :
-
Young’s modulus of the workpiece material (N/mm2)
- E t :
-
Young’s modulus of the tool material (N/mm2)
- e 2 :
-
Segment of serrated chip (mm)
- f :
-
Feed (mm/rev)
- f s :
-
Segmentation frequency (Hz)
- F c :
-
Primary cutting force (N)
- F f :
-
Feed force (N)
- F p :
-
Perpendicular force (N)
- G f :
-
Hillerborg’s fracture energy (J/m)
- h 1 :
-
Theoretical chip thickness, uncut chip thickness (mm)
- h 2 :
-
True chip thickness, deformed chip thickness (mm)
- k w :
-
Thermal conductivity of the workpiece material (W/(m⋅K))
- k t :
-
Thermal conductivity of the tool material (W/(m⋅K))
- l r :
-
Contact length on the rake face (mm)
- m :
-
Thermal softening coefficient in Johnson-Cook
- n :
-
Strain hardening exponent in Johnson-Cook
- P :
-
Hydrostatic stress (N/mm2)
- r β :
-
Edge radius mm
- r ε :
-
Nose radius mm
- T c l :
-
Tangential force acting on the clearance face (N)
- T r :
-
Tangential force acting on the rake face (N)
- u :
-
Plastic displacement (mm)
- u f :
-
Plastic displacement at failure (mm)
- u :
-
Displacement vector (mm)
- v c :
-
Cutting speed (m/min)
- v x :
-
Velocity in x-direction (m/min)
- v y :
-
Velocity in y-direction (m/min)
- v z :
-
Velocity in z-direction (m/min)
- α :
-
Clearance angle
- α L,w :
-
Thermal expansion of the workpiece material (K-1)
- γ :
-
Rake angle
- ε :
-
Strain
- ε f :
-
Johnson-Cook fracture strain
- Δε :
-
Strain increment
- \(\dot {\varepsilon }\) :
-
Strain rate (s-1)
- \(\dot {\varepsilon }_{0}\) :
-
Reference strain rate (s-1)
- \(\dot {\varepsilon }^{*}\) :
-
Dimensionless strain rate
- κ :
-
Major cutting angle
- 𝜃 :
-
Temperature (K)
- 𝜃 0 :
-
Bulk temperature of the workpiece material (K)
- 𝜃 m :
-
Melt temperature of the workpiece material (K)
- 𝜃 ∗ :
-
Homologous temperature
- λ :
-
Inclination angle
- λ h :
-
Chip compression ratio
- μ :
-
Sliding friction coefficient
- ν w :
-
Poisson’s ratio of the workpiece material
- ν t :
-
Poisson’s ratio of the tool material
- ρ w :
-
Density of the workpiece material (kg/m3)
- ρ t :
-
Density of the tool material (kg/m3)
- \(\bar {\sigma }\) :
-
Flow stress (N/mm2)
- σ 1 :
-
Maximal global principal stress (N/mm2)
- σ e :
-
Maximum global effective stress (N/mm2)
- σ ∗ :
-
Stress triaxiality (N/mm2)
- σ n :
-
Normal stress along the tool-chip interface (N/mm2)
- σ y :
-
Uniaxial yield stress of the workpiece material (N/mm2)
- σ :
-
Stress vector (N/mm2)
- τ f :
-
Frictional stress along the tool-chip interface (N/mm2)
- τ y :
-
Shear strength (N/mm2)
- ω :
-
Scalar damage parameter
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Funding
This work was co-funded by the European Union’s Horizon 2020 Research and Innovation Programme under Flintstone2020 project (grant agreement No 689279). It is also a part of the strategic research programme of the Sustainable Production Initiative SPI, involving cooperation between Lund University and Chalmers University of Technology.
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Agmell, M., Bushlya, V., Laakso, S.V.A. et al. Development of a simulation model to study tool loads in pcBN when machining AISI 316L. Int J Adv Manuf Technol 96, 2853–2865 (2018). https://doi.org/10.1007/s00170-018-1673-y
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DOI: https://doi.org/10.1007/s00170-018-1673-y