Chip morphology predictions while machining hardened tool steel using finite element and smoothed particles hydrodynamics methods

Usama Umer, Jaber Abu Qudeiri, Mohammad Ashfaq, Abdulrahman Al-Ahmari

Research output: Contribution to journalArticlepeer-review

7 Citations (Scopus)

Abstract

Chip morphology predictions in metal cutting have always been challenging because of the complexity of the various multiphysical phenomena that occur across the tool-chip interface. An accurate prediction of chip morphology is a key factor in the assessment of a particular machining operation with regard to both tool performance and workpiece quality. Although finite element (FE) models are being developed over the last two decades, their capabilities in modeling correct material flow around the tool tip with shear localization are very limited. FE models with an arbitrary Lagrangian Eulerian (ALE) approach are able to simulate correct material flow around the tool tip. However, these models are unable to predict any shear localization based on material flow criteria. On the other hand, FE models with a Lagrangian formulation can simulate shear localization in the chip segments; they need to make use of a mesh-based chip separation criterion that significantly affects material flow around the tool tip. In this study a mesh-free method viz. smoothed particles hydrodynamics (SPH) is implemented to simulate shear localization in the chip while machining hardened steel. Unlike other SPH models developed by some researchers, this model is based on a renormalized formulation that can consider frictional stresses along the tool-chip interface giving a realistic chip shape and material flow. SPH models with different cutting parameters are compared with the traditional FE models and it has been found that the SPH models are good for predicting shear localized chips and do not need any geometric or mesh-based chip separation criteria.

Original languageEnglish
Pages (from-to)873-885
Number of pages13
JournalJournal of Zhejiang University: Science A
Volume17
Issue number11
DOIs
Publication statusPublished - Nov 1 2016
Externally publishedYes

Keywords

  • Chip morphology
  • Finite element (FE)
  • Hardened tool steel
  • Serrated chips
  • Smoothed particles hydrodynamics (SPH)

ASJC Scopus subject areas

  • Engineering(all)

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