Machining Simulation of Ductile Iron and Its Constituents, Part 2: Numerical Simulation and Experimental Validation of Machining

[+] Author and Article Information
L. Chuzhoy

Caterpillar Inc., Technical Center, Peoria, IL 61525

R. E. DeVor, S. G. Kapoor

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

J. Manuf. Sci. Eng 125(2), 192-201 (Apr 15, 2003) (10 pages) doi:10.1115/1.1557295 History: Received June 01, 2001; Revised October 01, 2002; Online April 15, 2003
Copyright © 2003 by ASME
Your Session has timed out. Please sign back in to continue.


Strenkowski,  J. S., and Caroll,  J. T., 1985, “A Finite Element Model of Orthogonal Metal Cutting,” ASME J. Eng. Ind., 107, pp. 349–354.
Iwata,  K., Osakada,  K., and Terasaka,  Y., 1984, “Process Modeling of Orthogonal Cutting by the Rigid-Plastic Finite Element Method,” ASME J. Eng. Mater. Technol., 106, pp. 132–138.
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, p. 162.
Bammann,  D. J., and Johnson,  G. C., 1987, “On the Kinematics of Finite-Deformation Plasticity,” Acta Mech., 70, pp. 1–13.
SAS IP, Inc., 1998, ANSYS Modeling and Meshing Guide, 3rd Edition.
Bammann, D. J., Chiesa, M. L., and Johnson, G. C., 1996, “Modeling Large Deformation and Failure in Manufacturing Processes,” Theoretical and Applied Mechanics, pp. 359–376, Tatsumi, Wanabe, Kambe, eds.
Hibbitt, Karlson, and Sorensen, 1998, ABAQUS User’s and Theory Manuals, Version 5.8.
Cook, R. D., Malkus, D. S., and Plesha, M. E., 1989, Concepts and Applications of Finite Element Analysis, 3rd Edition, John Wiley & Sons, pp. 558–561.
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.
Shaw, M. C., 1984, Metal Cutting Principles, Bookcraft Ltd.
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 Iron,” AFS Casting Congress, Pittsburgh, PA.
Ceretti,  E., Fallbohmer,  , and Wu,  W. T., and Altan,  T., 1996, “Application of 2D FEM to Chip Formation in Orthogonal Cutting,” J. Mater. Process. Technol., 59, pp. 169–180.
Komanduri,  R., Schroeder,  T., Hazra,  J., von Turkovich,  B. F., and Flom,  D. G., 1982, “On the Catastrophic Shear Instability in High Speed Machining of an AISI 4340 Steel,” ASME J. Eng. Ind., 104, pp. 121–131.
Fu,  H. J., DeVor,  R. E., and Kapoor,  S. G., 1984, “A Mechanistic Model for Prediction of the Force System in Face Milling Operations,” ASME J. Eng. Ind., 106, pp. 81–88.


Grahic Jump Location
Simulated workpiece microstructure for ductile iron
Grahic Jump Location
Machining forces from cutting simulation of (a) pearlite, (b) ferrite, (c) ductile iron
Grahic Jump Location
Influence of chip formation on cutting and thrust forces for machining of pearlite (case 1)
Grahic Jump Location
Chip formation and temperature distribution during machining simulation of pearlite
Grahic Jump Location
Predicted chip morphology for machining of (a) pearlite-case 1, (b) pearlite-case 2, (c) pearlite-case 3, (d) pearlite-case 4, (e) ferrite case 1, (f ) ferrite-case 2, (g) ferrite-case 3, (h) ferrite-case 4
Grahic Jump Location
Pearlite chip dimensions for case 1 machining parameters
Grahic Jump Location
Simulated deformed grains of ductile iron at cutting distance of (a) 0.06 mm, (b) 0.17 mm, (c) 0.28 mm, (d) 0.40 mm
Grahic Jump Location
Samples of measured machining forces from cutting of with parameters of (a) pearlite, (b) ferrite, (c) ductile iron
Grahic Jump Location
Photomicrographs of machined chips of (a) pearlite, (b) ferrite, (c) ductile iron, (d) ductile iron-enlargement of (c)
Grahic Jump Location
Computed equivalent stress for case 3 at t=0.00012 s with (a) ferritic workpiece, (b) ductile iron workpiece




Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In