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Research Papers

A Metallo-Thermomechanically Coupled Analysis of Orthogonal Cutting of AISI 1045 Steel

[+] Author and Article Information
Hongtao Ding

 Center for Laser-Based Manufacturing, School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907

Yung C. Shin1

 Center for Laser-Based Manufacturing, School of Mechanical Engineering, Purdue University, West Lafayette, IN 47907shin@purdue.edu

1

Corresponding author.

J. Manuf. Sci. Eng 134(5), 051014 (Sep 28, 2012) (12 pages) doi:10.1115/1.4007464 History: Received October 07, 2011; Revised August 08, 2012; Published September 25, 2012; Online September 28, 2012

Materials often behave in a complicated manner involving deeply coupled effects among stress/stain, temperature, and microstructure during a machining process. This paper is concerned with prediction of the phase change effect on orthogonal cutting of American Iron and Steel Institute (AISI) 1045 steel based on a true metallo-thermomechanical coupled analysis. A metallo-thermomechanical coupled material model is developed and a finite element model (FEM) is used to solve the evolution of phase constituents, cutting temperature, chip morphology, and cutting force simultaneously using abaqus . The model validity is assessed using the experimental data for orthogonal cutting of AISI 1045 steel under various conditions, with cutting speeds ranging from 198 to 879 m/min, feeds from 0.1 to 0.3 mm, and tool rake angles from −7 deg to 5 deg. A good agreement is achieved in chip formation, cutting force, and cutting temperature between the model predictions and the experimental data.

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References

Figures

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Figure 1

Metallo-thermomechanical coupling in cutting of steels (adapted from Ref. [5])

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Figure 2

Phase changes in hypoeutectoid steel during heating (adapted from Ref. [10])

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Figure 3

Temperature-dependent physical properties of phases for AISI 1045 steel (data from Refs. [25-29])

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Figure 4

Constitutive model predictions versus SHPB test results (SHPB data from Ref. [16])

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Figure 5

Flowchart for implementation of the material model

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Figure 6

CEL model setup for orthogonal cutting of AISI 1045 steel (adapted from Ref. [41])

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Figure 7

Predictions of temperature, von Mises stress, and phase field for tests A7 and A8

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Figure 8

Comparison of the deformed chip thickness predicted with the experimental data from Refs. [17] and [40]

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Figure 9

Prediction of phase fraction of austenite in the chip and comparison of the predicted Tint with experimental data from Ref. [17]

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Figure 10

Comparison of the predicted cutting force with experimental data from Refs. [17] and [40]

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Figure 11

Predictions of von Mises stress without phase transformation effect for tests A7 and A8

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Figure 12

Comparison of the cutting temperature and cutting force measured by Ivester [17] and predicted by extended Oxley’s theory [38], no metallurgical coupling and proposed metallo-thermomechanical analysis

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