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research-article

Hybrid DIC-FEM approach for modeling of orthogonal cutting process

[+] Author and Article Information
Dong Zhang

State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan 430074, China
zhangdong@hust.edu.cn

Xiao-Ming Zhang

State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan 430074, China
zhangxm.duyi@gmail.com

Han Ding

State Key Laboratory of Digital Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan 430074, China
famt@hust.edu.cn

1Corresponding author.

ASME doi:10.1115/1.4038998 History: Received June 21, 2017; Revised December 22, 2017

Abstract

Cutting process modelling is still a great challenge due to the severe plastic deformation of the workpiece and intense friction between the workpiece and tool. Nowadays, a novel experimental approach based on digital image correlation technique (DIC) has been utilized to study the severe deformation of the workpiece. However, the experimentally measured velocity field does not necessarily satisfy the equilibrium equation that is one of the most important governing equations in solid mechanics due to the measurement errors; hence, accurate stress fields could hardly be derived. In this paper, we propose a hybrid DIC-FEM approach to optimize the velocity field and generate a stress field that is in equilibrium state. The deviatoric stresses of the main deformation region are calculated by tracking the deformations of the material particles, and the hydrostatic pressures are acquired through solving over-constrained equations derived through finite element method (FEM). Then, the velocity fields are optimized to satisfy the equilibrium equation and the boundary conditions. To validate this approach, the deformations including the velocity and strain yield by the hybrid method are compared with the initial values. The stress fields are presented to demonstrate the satisfactions of the equilibrium equation and the boundary conditions. Moreover, cutting forces calculated through integration of the stress fields are compared against the FEM simulations and the experimentally measured ones.

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