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
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Computed equivalent stress for case 3 at t=0.00012 s with (a) ferritic workpiece, (b) ductile iron workpiece
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Simulated workpiece microstructure for ductile iron
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Machining forces from cutting simulation of (a) pearlite, (b) ferrite, (c) ductile iron
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Influence of chip formation on cutting and thrust forces for machining of pearlite (case 1)
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Chip formation and temperature distribution during machining simulation of pearlite
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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
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Pearlite chip dimensions for case 1 machining parameters
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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
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Samples of measured machining forces from cutting of with parameters of (a) pearlite, (b) ferrite, (c) ductile iron
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Photomicrographs of machined chips of (a) pearlite, (b) ferrite, (c) ductile iron, (d) ductile iron-enlargement of (c)



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