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TECHNICAL PAPERS

Machining Simulation of Ductile Iron and Its Constituents, Part 1: Estimation of Material Model Parameters and Their Validation

[+] Author and Article Information
L. Chuzhoy

Caterpillar Inc., Technical Center, Peoria, IL 61525

R. E. DeVor, S. G. Kapoor, A. J. Beaudoin

Department of Mechanical and Industrial Engineering, University of Illinois, Urbana-Champaign, IL 61801

D. J. Bammann

Sandia National Laboratory, Livermore, CA 94550

J. Manuf. Sci. Eng 125(2), 181-191 (Apr 15, 2003) (11 pages) doi:10.1115/1.1557294 History: Received June 01, 2001; Revised October 01, 2002; Online April 15, 2003
Copyright © 2003 by ASME
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References

Soons, H. A., and Yaniv, S. L., 1995, “Precision in Machining: Research Challenges,” National Institute of Standards and Technology, NISTIR 5628.
Chuzhoy,  L., DeVor,  R. E., Kapoor,  S. G., and Bammann,  D. J., 2002, “Microstructure-level Modeling of Ductile Iron Machining,” ASME J. Manuf. Sci. Eng., 124, pp. 162–169.
Bammann, D. J., Chiesa, M. L., and Johnson, G. C., 1996, “Modeling Large Deformation and Failure in Manufacturing Processes,” Theoretical and Applied Mechanics, Tatsumi, Wanabe, Kambe, eds., pp. 359–376.
Voigt,  R. C., Marwanga,  R. O., and Cohen,  P. H., 1999, “Machinability of Gray Iron—Mechanics of Chip Formation,” International Journal of Cast Metal Research, 11 , pp. 567–572.
SAS IP, Inc, 1998, ANSYS Modeling and Meshing Guide, 3rd Edition.
Hibbitt, Karlson, and Sorensen, 1998, ABAQUS User’s and Theory Manuals, Version 5.8.
Dieter, G. E., 1986, Mechanical Metallurgy, McGraw-Hill, 3rd Edition.
Underwood, E. E., and Berry, J. T., 1982, “Quantitative Measurements of Cast Iron Microstructure,” AFS Transactions, pp. 755–766.
Instron Corporation, 1994, “Instron AlignPro Data Acquisition System,” M12-0800-1, Issue A.
Bammann,  D. J., 1990, “Modeling Temperature and Strain Dependent Large Deformation of Metals,” Appl. Mech. Rev., 43, pp. 312–319.
Hertzberg, R. W., 1995, Deformation and Fracture Mechanics of Engineering Materials, John Wiley & Sons, 4th Edition, New York.
Cohen, P. H., Voigt, R. C., and Marwanga, R. O., 2000, “Influence of Graphite Morphology and Matrix Structure on Chip Formation During Machining of Ductile Irons,” AFS Casting Congress.
Farren,  W. S., and Taylor,  G. I., 1925, “The Heat Developed during Plastic Extrusion of Metals,” Proc. R. Soc. London, Ser. A, 107, pp. 422–451.

Figures

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Distribution of hydrostatic stress during machining of ductile iron 2
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Material damage accumulated during machining of ductile iron 2
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Photomicrograph of microstructure used for validation of material model: (a) ferrite, (b) pearlite, (c) pearlitic-ferritic ductile iron
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Stress-strain curve of ferrite due to reverse loading
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Stress-strain curve of pearlite due to reverse loading
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Stress-strain curve of pearlitic-ferritic ductile iron due to reverse loading
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Fracture behavior of (a) ferrite, (b) pearlite, (c) pearlitic-ferritic ductile iron
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Distribution of (a) hydrostatic stress, (b) equivalent stress near the end of loading
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Damage initiation in notched specimen
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Computed load-displacement curves for notched specimens made from (a) ferritic steel, (b) pearlitic steel
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Modeled geometry of ductile iron notched specimen-enlarged notch region
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Equivalent stress distribution in ductile iron notched specimen
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Hydrostatic stress distribution in ductile iron notched specimen
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Computed load-displacement curves for ductile iron notched specimens
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Chip formation during machining simulation of pearlite using material model (a) with the MSRL effect, (b) without the MSRL effect
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Photomicrograph of pearlite chip
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Effect of material softening on cutting force prediction
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Shear stress reversal during machining
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Accumulated damage sensitivity: (a) nt=4 and np=16, (b) nt=6 and np=11(nt and np are damage exponents for ferrite and pearlite, respectively)

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