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Research Papers

A Modified Johnson–Cook Constitutive Model and Its Application to High Speed Machining of 7050-T7451 Aluminum Alloy

[+] Author and Article Information
Bing Wang

Mem ASME
School of Mechanical Engineering,
Shandong University,
Jinan 250061, Shandong, China;
School of Materials Science and Engineering,
Shandong University,
Jinan 250061, Shandong, China;
Key Laboratory of High Efficiency and
Clean Mechanical Manufacture of MOE/Key
National Demonstration Center for Experimental
Mechanical Engineering Education,
Jinan 250061, Shandong, China
e-mail: sduwangbing@gmail.com

Zhanqiang Liu

Mem ASME
School of Mechanical Engineering,
Shandong University,
Jinan 250061, Shandong, China;
Key Laboratory of High Efficiency and Clean
Mechanical Manufacture of MOE/Key National
Demonstration Center for Experimental
Mechanical Engineering Education,
Jinan 250061, Shandong, China
e-mail: melius@sdu.edu.cn

Qinghua Song

School of Mechanical Engineering,
Shandong University,
Jinan 250061, Shandong, China
e-mail: ssinghua@sdu.edu.cn

Yi Wan

School of Mechanical Engineering,
Shandong University,
Jinan 250061, Shandong, China
e-mail: wanyi@sdu.edu.cn

Xiaoping Ren

School of Mechanical Engineering,
Shandong University,
Jinan 250061, Shandong, China
e-mail: renxiaoping@sdu.edu.cn

1Corresponding author.

Manuscript received August 1, 2018; final manuscript received October 29, 2018; published online November 26, 2018. Assoc. Editor: Tony Schmitz.

J. Manuf. Sci. Eng 141(1), 011012 (Nov 26, 2018) (15 pages) Paper No: MANU-18-1576; doi: 10.1115/1.4041915 History: Received August 01, 2018; Revised October 29, 2018

Constitutive model is the most commonly used method to describe the material deformation behavior during machining process. This paper aims to investigate the material dynamic deformation during high speed machining of 7050-T7451 aluminum alloy with the aid of split Hopkinson pressure bar (SHPB) system and finite element (FE) analysis. First, the quasi static and dynamic compression behaviors of 7050-T7451 aluminum alloy are tested at different loading conditions with a wide range of strain rates (0.001 s, 4000 s, 6000 s, 8000 s, and 12,000 s) and temperatures (room temperature, 100 °C, 200 °C, 300 °C, and 400 °C). The influences of temperature on strain and strain rate hardening effects are revealed based on the flow stress behavior and microstructural alteration of tested specimens. Second, a modified Johnson–Cook (JCM) constitutive model is proposed considering the influence of temperature on strain and strain rate hardening. The prediction accuracies of Johnson–Cook (JC) and JCM constitutive models are compared, which indicates that the predicted flow stresses of JCM model agree better with the experimental results. Then the established JC and JCM models are embedded into FE analysis of orthogonal cutting for 7050-T7451 aluminum alloy. The reliabilities of two material models are evaluated with chip morphology and cutting force as assessment criteria. Finally, the material dynamic deformation behavior during high speed machining and compression test is compared. The research results can help to reveal the dynamic properties of 7050-T7451 aluminum alloy and provide mechanical foundation for FE analysis of high speed machining.

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Figures

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Fig. 1

Research scope of this paper

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Fig. 2

Metallographic microstructure of tested material 7050-T7451 aluminum alloy (a) optical micrograph and (b) SEM micrograph

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Fig. 3

Specimens with different sizes for varied loading conditions

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Fig. 4

Setup of split Hopkinson compression bar for dynamic tests (a) schematic diagram and (b) equipment photo

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Fig. 5

Stress wave measured at the loading rate of 8 × 103 s and room temperature

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Fig. 6

Flow stress curves of 7050-T7451 aluminum alloy obtained during dynamic compression tests at different temperatures and varied strain rates of (a) 4000 s, (b) 6000 s, (c) 8000 s and (d) 12,000 s

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Fig. 7

Cross sectional microstructure of deformed specimens observed along the radial direction after dynamic compression tests at different loading conditions (a) T = 25 °C, ε˙ = 4000 s, (b) T = 25 °C, ε˙= 8000 s, (c) T = 200 °C, ε˙ = 8000 s, (d) T = 400 °C, ε˙ = 8000 s, (e) T = 25 °C, ε˙ = 12,000 s, (f) T = 200 °C, ε˙ = 12,000 s

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Fig. 8

Variation of average strain hardening rate at different loading conditions

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Fig. 9

Variation of average strain rate hardening rate at different loading conditions

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Fig. 10

Comparison of experimental and predicted flow stresses at different loading conditions

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Fig. 11

Chip morphologies produced at the cutting speed of 2000 m/min for 7050-T7451 aluminum alloy with different material models (a) JC constitutive model and (b) JCM constitutive model

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Fig. 12

Micrographs of chip cross sections produced at different cutting speeds for 7050-T7451 aluminum alloy (a) 500 m/min, (b) 1000 m/min, (c) 2000 m/min, (d) 3000 m/min, (e) 4000 m/min, (f) 5000 m/min

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Fig. 13

Geometrical dimensions of serrated chips for 7050-T7451 aluminum alloy produced at different cutting speeds (a) the maximum chip height and (b) height of chip continuous section

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Fig. 14

Chip serration degree for 7050-T7451 aluminum alloy produced at different cutting speeds

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Fig. 15

Cutting force curves produced at the cutting speed of 2500 m/min for 7050-T7451 aluminum alloy (a) experimental results and (b) simulation results

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Fig. 16

Average cutting forces produced at different cutting speeds during high speed machining of 7050-T7451 aluminum alloy (a) cutting force component and (b) thrust force component

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