Measurements and Simulations of Temperature and Deformation Fields in Transient Metal Cutting

[+] Author and Article Information
Yogesh K. Potdar, Alan T. Zehnder

Department of Theoretical and Applied Mechanics, Cornell University, Ithaca, NY 14853

J. Manuf. Sci. Eng 125(4), 645-655 (Nov 11, 2003) (11 pages) doi:10.1115/1.1596571 History: Received December 01, 2001; Revised January 01, 2003; Online November 11, 2003
Copyright © 2003 by ASME
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Schematic of orthogonal cutting showing a typical region on which IR detectors are focused in a single experiment.
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(a) Schematic of FE model showing contact pairs, (b) finite element mesh of the workpiece, chip layer and cutting tool.
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(a) Variation of initial yield stress with temperature. (b) variation of elastic modulus with temperature. (c) strain hardening under quasistatic loading. (d) dependence of flow stress on strain rate, data points for Al6061 45 and Ti-6Al-4V 46 are from experiments and those for steel are from Shawki-Clifton model 44. Lines show best fit curves obtained using parameters in Table 1.
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FE simulated cutting at 4.3 m/s, μ=0.3. The contour plot shows equivalent plastic strains. Localized regions of plastic strain form bands on the chip surface, indicating onset of segmented chip formation (a) Al6061-T6, d=250 μm (b) Ti-6Al-4V, d=150 μm.
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Variation of maximum temperature with gap conductance for 1018 CR steel, Al6061-T6, and Ti-6Al-4V. FE simulations using critical distance criterion.
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Change in FE (using critical distance and μ=0.3) temperature field (°C) with gap conductance (k) while cutting 1018 CR steel (a) low conductance, k=104 W/m2⋅K (b) high conductance, k=107 W/m2⋅K.
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Experimental data while cutting 1018 CRS. Detector array is focused along the original free surface of the workpiece (250 μm above the line of cut).
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Temperatures, experimental and FE comparison of evolution of temperature at a point 1.55 mm from start of cut. (a) 1018 CR steel (b) Al6061-T6 (c) Ti-6Al-4V.
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Max Temperatures: Experimental and FE (using critical distance criterion) vs. height (a) 1018 CR steel (b) Al6061-T6 (c) Ti-6Al-4V.
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IR signals at different heights for (a) 1018 CR steel (b) Al6061-T6 (c) Ti-6Al-4V.
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Comparison of experimental and FE (using critical stress criterion and μ=0.3) temperature field ahead of cutting tool while cutting 1018 CR steel at 4.3 m/s, 250 μm depth of cut, 350 μs after the beginning of cut.
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Comparison of experimental and FE (using critical distance criterion and μ=0.3) temperature field ahead of cutting tool while cutting Al6061-T6 at 4.3 m/s, 250 μm depth of cut, 350 μs after the beginning of cut.
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Comparison of experimental and FE temperature field ahead of cutting tool while cutting Ti-6Al-4V at 4.3 m/s, 150 μm depth of cut, 150 μs after the beginning of cut (a) experimental (b) FE critical distance, μ=0.3 (c) FE critical stress, μ=0.1, (d) FE critical stress, μ=0.3
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(a) SEM image of deformed chip (b) images processed by Matlab (c) maximum principal stretches, distance on horizontal axis is measured from the surface of the chip that passes over the rake face of the tool




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