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TECHNICAL PAPERS

Mechanistic Cutting Process Calibration via Microstructure-Level Finite Element Simulation Model

[+] Author and Article Information
Sunghyuk Park, S. G. Kapoor, R. E. DeVor

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

J. Manuf. Sci. Eng 126(4), 706-709 (Feb 04, 2005) (4 pages) doi:10.1115/1.1813480 History: Received June 19, 2003; Revised August 30, 2004; Online February 04, 2005
Copyright © 2004 by ASME
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References

Merchant,  M. E., 1945, “Mechanics of Metal Cutting Process. I. Orthogonal Cutting and a Type 2 Chip,” J. Appl. Phys., 16, pp. 267–275.
Martellotti,  M. E., 1941, “An Anaylysis of the Milling Process,” Trans. ASME, 63, pp. 677–700.
Martellotti,  M. E., 1945, “An Analysis of the Milling Process Part II, Down Milling,” Trans. ASME, 75, p. 233.
Sabberwal,  A. J. P., 1960, “Chip Section and Cutting Forces During the Milling Operations,” CIRP Ann., 8, pp. 197–203.
DeVor, R. E., Kline, W. A., and Zdeblick, W. J., 1980, “A Mechanistic Model for the Force System in End Milling With Application to Machining Airframe Structures,” Proc. of 8th North American Metalworking Research Conference, Rolla, MO, Society of Manufacturing Engineers (SME), Dearborn, MI, pp. 297–303.
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.
Sutherland, J. W., Subramani, G., Kuhl, M. J., DeVor, R. E., and Kapoor, S. G., 1988, “An Investigation Into the Effect of Tool and Cut Geometry on Cutting Force System Prediction Models,” Proc. 16th North American Manufacturing Research Conference, Urbana, IL, Society of Manufacturing Engineers (SME), Dearborn, MI, Vol. 16, pp. 264–272.
Endres,  W. J., DeVor,  R. E., and Kapoor,  S. G., 1995, “A Dual Mechanism Approach to the Prediction of Machining Forces—Parts 1 and 2,” ASME J. Eng. Ind., 117, pp. 526–542.
Chuzhoy,  L., Kapoor,  S. G., DeVor,  R. E., and Bammann,  D. J., 2002, “Microstructure Level Modeling of Ductile Iron Machining,” ASME J. Manuf. Sci. Eng., 124, pp. 162–169.
Chuzhoy,  L., Kapoor,  S. G., DeVor,  R. E., Beaudoin,  A. J., and Bamman,  D. J., 2003, “Machining Simulation of Ductile Iron and Its Constituents, Part 1: Estimation of Material Model Parameters and Their Validation,” ASME J. Manuf. Sci. Eng., 125, pp. 181–191.
Chuzhoy,  L., Kapoor,  S. G., and DeVor,  R. E., 2003, “Machining Simulation of Ductile Iron and Its Constituents, Part 2: Numerical Simulation and Experimental Validation of Machining,” ASME J. Manuf. Sci. Eng., 125, pp. 192–201.
Bammann,  D. J., and Thomson,  G. C., 1987, “On the Kinematics of Finite Deformation Plasticity,” Acta Mech., 80, pp. 1–13.
Bammann, D. J., Chiesa, M. L., and Johnson, G. C., 1996, “Modeling Large Deformation and Failure in Manufacturing Process,” Theoretical and Applied Mechanics, T. Tatsumi, E. Wanabe, and T. Kambe, eds., Berlin, New York, 19 , pp. 359–376.
Stephenson,  D. A., and Bandyopadhyay,  P., 1997, “Process-Independent Force Characterization for Metal Cutting Simulation,” ASME J. Eng. Mater. Technol., 119, pp. 86–94.
Shin,  Y. C., and Waters,  A. J., 1997, “A New Procedure to Determine Instantaneous Cutting Force Coefficients for Machining Force Prediction,” Int. J. Mach. Tools Manuf., 37, pp. 1337–1351.
Jayaram,  S., Kapoor,  S. G., and DeVor,  R. E., 2001, “Estimation of the Specific Cutting Pressures for Mechanistic Cutting Force Model,” Int. J. Mach. Tools Manuf., 41, pp. 265–281.
Parakkal,  G., Zhu,  R., Kapoor,  S. G., and DeVor,  R. E., 2002, “Modeling of Turning Process Cutting Forces for Grooved Tools,” Int. J. Mach. Tools Manuf., 42, pp. 179–191.

Figures

Grahic Jump Location
Actual and simulated microstructures of ASTM A536 grade 65-45-12 (25% pearlite): (a) Actual; (b) Simulated
Grahic Jump Location
Actual and simulated microstructures of ASTM A536 grade 80-55-06 (70% pearlite): (a) Actual; (b) Simulated
Grahic Jump Location
Actual and simulated microstructures of gray iron: (a) Actual; (b) Simulated
Grahic Jump Location
Actual and simulated microstructures of AISI 1018 steel: (a) Actual; (b) Simulated
Grahic Jump Location
Actual and simulated microstructures of AISI 1045 steel: (a) Actual; (b) Simulated
Grahic Jump Location
Graphite shape factor, b/a: 1 for ductile iron and 0.1 for gray iron

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