AUTHORS: Marco Piccinini, Laurent Humbert, Paul Xirouchakis

Download as PDF

ABSTRACT: A three dimensional (3D) fully coupled thermal-mechanical analysis is presented in order to evaluate the influence of certain cutting parameters as well as dual phase microstructure on the orthogonal micro cutting process of steels (in particular, AISI 1045 steel), for which the size of heterogeneities is of the order of magnitude of the uncut chip thickness and tool edge radius. The simulated microstructure is composed of successive hexagonal close-packed layers with grain size control allowing to reproduce the desired fraction volume of the two considered constituents. Based on Johnson-Cook failure criteria inside the constitutive phases and a cohesive zone model along their interfaces, the numerical model is able to take into account both intra and inter granular damage initiation and evolution. Through an analysis of variance (ANOVA) method, a systematic study of the 3D microstructural effects and the relative effect of the pearlite-ferrite phases with respect to cutting settings (cutting speed, tool rake angle and tool radius) is carried out.

KEYWORDS: Micro-cutting, FEA, Inter/intra granular damage, 3D microstructure modeling

REFERENCES:

[1] Markopoulos, A. P. (2013) Finite Element Method in Machining Processes. Springer, London, Heidelberg, New York, Dordrecht.

[2] Chuzhoy, L.; DeVor, R.E.; Kapoor, S.G.; Bamman, D.J. (2002) Microstructure-Level Modelling of Ductile Iron Machining. ASME Journal of Manufacturing Science and Engineering, 124: 162-169.

[3] Chuzhoy, L.; DeVor, R.E.; Kapoor, S.G.; Beaudoin, A. J.; Bamman D.J. (2003) Machining Simulation of Ductile Iron and Its Constituents, Part1: Estimation of Material Model Parameters and Their Validation. ASME Journal of Manufacturing Science and Engineering, 125: 181-191.

[4] Chuzhoy, L.; DeVor, R.E.; Kapoor, S.G. (2003) Machining Simulation of Ductile Iron and Its Constituents, Part2: Numerical Simulation and Experimental Validation of Machining. ASME Journal of Manufacturing Science and Engineering, 125: 192-201.

[5] Simoneau, A.; Ng, E.; Elbestawi, M.A. (2006) Surface defects during microcutting. International Journal of Machine Tools and Manufacture, 46: 1378-1387.

[6] Simoneau, A.; Ng, E.; Elbestawi, M.A. (2006) The effect of microstructure on chip formation and surface defects in microscale, mesoscale and macroscale cutting of steel. CIRP Annals – Manufacturing Technology, 55 (1): 97-102.

[7] Simoneau, A.; Ng, E.; Elbestawi, M.A. (2007) Grain size and orientation effects when microcutting AISI 1045 steel. CIRP Annals - Manufacturing Technology, 56 (1): 57-60.

[8] Dornfeld, D.A.; Oliveira, J.F.G.; Lee, D.; Valente, C.M.O. (2003) Analysis of Tool and Workpiece Interaction in Diamond Turning Using Graphical Analysis of Acoustic Emission. CIRP Annals – Manufacturing Technology, 52 (1): 479- 482.

[9] Zhang, Y.; Mabrouki, T.; Nelias, D.; Courbon C.; Rech, J.; Gong , Y. (2012) Cutting simulation capabilities based on crystal plasticity theory and discrete cohesive elements. Journal of Materials Processing Technology, 212: 936-953.

[10] Vogler, M.P.; DeVor, R. E.; Kapoor, S.G. (2003) Microstructure-Level Force Prediction Model for Micro-milling of Multi-Phase Materials. ASME Journal of Manufacturing Science and Engineering, 125: 202-209.

[11] Abouridouane, M.; Klocke, F.; Lung, D.; Adams, O. (2012) A new 3D multiphase FE model for micro cutting ferritic- pearlitic carbon steels. CIRP Annals – Manufacturing Technology, 61: 71- 71.

[12] ABAQUS (2014). Abaqus Scripting User’s Guide Version 6.14. Dassault Systems.

[13] Mabrouki, T.; Rigal, J.F. (2006) A contribution to a qualitative understanding of thermo-mechanical effects during chip formation in hard turning. Journal of Materials Processing Technology, 176: 214-221.

[14] Jadhav, D.N.; Maiti S.K. (2010) Characterization of stable crack growth through AISI 4340 steel using cohesive zone modeling and CTOD/CTOA criterion, 240: 713-721.

[15] Mohammed, W.M.; Ng, E.; Elbestawi, M.A. (2012) Modeling the effect of compacted graphite iron microstructure on cutting forces and tool wear, 5:87-101.

[16] Courbon, C.; Mabrouki, T.; Rech, J.; Mazuyer, D.; D’Eramo, E. (2011) New thermal issues on the modelling of tool-workpiece interaction: application to dry cutting of AISI 1045 steel. Advanced Materials Research, 223: 286-295.

[17] Duan, C.Z.; Dou, T.; Cai, Y.J.; Li, Y.Y. (2011) Finite Element Simulation and Experiment of Chip Formation Process during High Speed Machining of AISI 1045 Hardened Steel. AMAE Production and Industrial Engineering, 02 (01): 28-32.