Details
| Original language | English |
|---|---|
| Pages (from-to) | 405-410 |
| Number of pages | 6 |
| Journal | Procedia CIRP |
| Volume | 31 |
| Publication status | Published - 3 Jun 2015 |
| Event | 15th CIRP Conference on Modelling of Machining Operations, CMMO 2015 - Karlsruhe, Germany Duration: 11 Jun 2015 → 12 Jun 2015 |
Abstract
In analysis of machining processes, finite element analysis is widely used to predict forces, stress distributions, temperatures and chip formation. However, constitutive models are not always available and simulation of cutting processes with complex tool geometries can lead to extensive computation time. This article presents an approach to determine constitutive parameters of the Johnson-Cook's flow stress model by inverse modelling as well as a methodology to predict process forces and temperatures for complex three-dimensional tools using Oxley's machining theory. In the first part of this study, an analytically based computer code combined with a particle swarm optimization (PSO) algorithm is used to identify constitutive models for 70MnVS4 and an aluminium-alloyed ultra-high-carbon steel (UHC-steel) from orthogonal milling experiments. In the second part, Oxley's predictive machining theory is coupled with a multi-dexel based material removal model. Contact zone information (width of cut, undeformed chip thickness, rake angle and cutting speed) are calculated for incremental segments on the cutting edge and used as input parameters for force and temperature calculations. Subsequently, process forces are predicted for machining using the inverse determined constitutive models and compared to actual force measurements. The suggested methodology has advantages regarding the computation time compared to finite element analyses.
Keywords
- Force, Material, Simulation
ASJC Scopus subject areas
- Engineering(all)
- Control and Systems Engineering
- Engineering(all)
- Industrial and Manufacturing Engineering
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In: Procedia CIRP, Vol. 31, 03.06.2015, p. 405-410.
Research output: Contribution to journal › Conference article › Research › peer review
}
TY - JOUR
T1 - Inverse Determination of Constitutive Equations and Cutting Force Modelling for Complex Tools Using Oxley’s Predictive Machining Theory
AU - Denkena, B.
AU - Grove, T.
AU - Dittrich, M. A.
AU - Niederwestberg, D.
AU - Lahres, M.
PY - 2015/6/3
Y1 - 2015/6/3
N2 - In analysis of machining processes, finite element analysis is widely used to predict forces, stress distributions, temperatures and chip formation. However, constitutive models are not always available and simulation of cutting processes with complex tool geometries can lead to extensive computation time. This article presents an approach to determine constitutive parameters of the Johnson-Cook's flow stress model by inverse modelling as well as a methodology to predict process forces and temperatures for complex three-dimensional tools using Oxley's machining theory. In the first part of this study, an analytically based computer code combined with a particle swarm optimization (PSO) algorithm is used to identify constitutive models for 70MnVS4 and an aluminium-alloyed ultra-high-carbon steel (UHC-steel) from orthogonal milling experiments. In the second part, Oxley's predictive machining theory is coupled with a multi-dexel based material removal model. Contact zone information (width of cut, undeformed chip thickness, rake angle and cutting speed) are calculated for incremental segments on the cutting edge and used as input parameters for force and temperature calculations. Subsequently, process forces are predicted for machining using the inverse determined constitutive models and compared to actual force measurements. The suggested methodology has advantages regarding the computation time compared to finite element analyses.
AB - In analysis of machining processes, finite element analysis is widely used to predict forces, stress distributions, temperatures and chip formation. However, constitutive models are not always available and simulation of cutting processes with complex tool geometries can lead to extensive computation time. This article presents an approach to determine constitutive parameters of the Johnson-Cook's flow stress model by inverse modelling as well as a methodology to predict process forces and temperatures for complex three-dimensional tools using Oxley's machining theory. In the first part of this study, an analytically based computer code combined with a particle swarm optimization (PSO) algorithm is used to identify constitutive models for 70MnVS4 and an aluminium-alloyed ultra-high-carbon steel (UHC-steel) from orthogonal milling experiments. In the second part, Oxley's predictive machining theory is coupled with a multi-dexel based material removal model. Contact zone information (width of cut, undeformed chip thickness, rake angle and cutting speed) are calculated for incremental segments on the cutting edge and used as input parameters for force and temperature calculations. Subsequently, process forces are predicted for machining using the inverse determined constitutive models and compared to actual force measurements. The suggested methodology has advantages regarding the computation time compared to finite element analyses.
KW - Force
KW - Material
KW - Simulation
UR - http://www.scopus.com/inward/record.url?scp=84939188338&partnerID=8YFLogxK
U2 - 10.1016/j.procir.2015.03.012
DO - 10.1016/j.procir.2015.03.012
M3 - Conference article
AN - SCOPUS:84939188338
VL - 31
SP - 405
EP - 410
JO - Procedia CIRP
JF - Procedia CIRP
SN - 2212-8271
T2 - 15th CIRP Conference on Modelling of Machining Operations, CMMO 2015
Y2 - 11 June 2015 through 12 June 2015
ER -