High speed machining (HSM) produces parts with substantially higher fatigue strength; increased subsurface micro-hardness and plastic deformation, mostly due to the ploughing of the cutting tool associated with residual stresses, and can have far more superior surface properties than surfaces generated by grinding and polishing. In this paper, a dynamics explicit Arbitrary Lagrangian Eulerian (ALE) based Finite Element Method (FEM) modeling is employed. FEM techniques such as adaptive meshing, explicit dynamics and fully coupled thermal-stress analysis are combined to realistically simulate high speed machining with an orthogonal cutting model. The Johnson-Cook model is used to describe the work material behavior. A detailed friction modeling at the tool-chip and tool-work interfaces is also carried. Work material flow around the round edge-cutting tool is successfully simulated without implementing a chip separation criterion and without the use of a remeshing scheme. Finite Element modeling of stresses and resultant surface properties induced by round edge cutting tools is performed as case studies for high speed machining of AISI 1045 and AISI 4340 steels, and Ti6Al4V titanium alloy.

Volume Subject Area:
Manufacturing (Research Oriented)
Topics:
Cutting tools, Finite element analysis, High speed machining, Modeling, Stress, Finite element methods, Cutting, Dynamics (Mechanics), Surface properties, Deformation, Fatigue strength, Flow (Dynamics), Friction, Grinding, Microhardness, Polishing, Residual stresses, Separation (Technology), Steel, Thermal stresses, Titanium alloys
1.
Usui, E. and Shirakashi, T., 1982, “Mechanics of machining -from descriptive to predictive theory. In on the art of cutting metals-75 years later,” ASME Publication PED, 7, 13–35.
2.
Komvopoulos
K.
and
Erpenbeck
S. A.
,
1991
, “
Finite element modeling of orthogonal metal cutting
,”
ASME Journal of Engineering for Industry
,
113
,
253
–
267
.
3.
Lin
Z. C.
and
Lin
S. Y.
,
1992
, “
A couple finite element model of thermo-elastic-plastic large deformation for orthogonal cutting
,”
ASME Journal of Engineering for Industry
,
114
,
218
–
226
.
4.
Zhang
B.
and
Bagchi
A.
,
1994
, “
Finite element simulation of chip formation and comparison with machining experiment
,”
ASME Journal of Engineering for Industry
,
116
,
289
–
297
.
5.
Shih
A. J.
,
1995
, “
Finite element simulation of orthogonal metal cutting
,”
ASME Journal of Engineering for Industry
,
117
,
84
–
93
.
6.
Strenkowski
J. S.
and
Carroll
J. T.
,
1985
, “
A finite element model of orthogonal metal cutting
,”
ASME Journal of Engineering for Industry
,
107
,
346
–
354
.
7.
Strenkowski
J. S.
and
Carroll
J. T.
,
1986
, “
Finite element models of orthogonal cutting with application to single point diamond turning
,”
International Journal of Mechanical Science
,
30
,
899
–
920
.
8.
Black
J. T.
and
Huang
J. M.
,
1996
, “
An evaluation of chip separation criteria for the fem simulation of machining
,”
ASME Journal of Manufacturing Science and Engineering
,
118
,
545
–
553
.
9.
Sekhon, G.S. and Chenot, J.L., 1992, “Some Simulation Experiments in Orthogonal Cutting,” Numerical Methods in Industrial Forming Processes, 901–906.
10.
Marusich
T. D.
and
Ortiz
M.
,
1995
, “
Modeling and simulation of high-speed machining
,”
International Journal for Numerical Methods in Engineering
,
38
,
3675
–
3694
.
11.
Ceretti
E.
,
Fallbo¨hmer
P.
,
Wu
W. T.
and
Altan
T.
,
1996
, “
Application of 2–D FEM to chip formation in orthogonal cutting
,”
Journal of Materials Processing Technology
,
59
,
169
–
181
.
12.
Leopold, J., Semmler, U. and Hoyer, K., 1999, “Applicability, robustness and stability of the finite element analysis in metal cutting operations,” Proceedings of the 2nd CIRP International Workshop on Modeling of Machining Operations, 81–94, Nantes, France, Jan. 1999.
13.
O¨zel
T.
and
Altan
T.
,
2000
, “
Determination of workpiece flow stress and friction at the chip-tool contact for high-speed cutting
,”
International Journal of Machine Tools and Manufacture
,
40
/
1
,
133
–
152
.
14.
Madhavan
V.
,
Chandrasekar
S.
and
Farris
T. N.
,
2000
, “
Machining as a wedge indentation
,”
Journal of Applied Mechanics
,
67
,
128
–
139
.
15.
Klocke
F.
,
Raedt
H.-W.
and
Hoppe
S.
,
2001
, “
2D-FEM simulation of the orthogonal high speed cutting process
,”
Machining Science and Technology
,
5
/
3
,
323
–
340
.
16.
Baker
M.
,
Rosler
J.
and
Siemers
C.
,
2002
, “
A finite element model of high speed metal cutting with adiabatic shearing
,”
Computers and Structures
,
80
,
495
–
513
.
17.
Rakotomalala
R.
,
Joyot
P.
and
Touratier
M.
,
1993
, “
Arbitrary Lagrangian-Eulerian thermomechanical finite element model of material cutting
,”
Communications in Numerical Methods in Engineering
,
9
,
975
–
987
.
18.
Olovsson
L.
,
Nilsson
L.
, and
Simonsson
K.
,
1999
, “
An ALE Formulation for the Solution of Two-Dimensional Metal Cutting Problems
,”
Computers and Structures
,
72
,
497
–
507
.
19.
Movahhedy
M. R.
,
Gadala
M. S.
, and
Altintas
Y.
,
2000
, “
FE Modeling of Chip Formation in Orthogonal Metal Cutting Process: An ALE Approach
,”
Machining Science and Technology
,
4
,
15
–
47
.
20.
Movahhedy
M. R.
,
Altintas
Y.
and
Gadala
M. S.
,
2002
, “
Numerical analysis of metal cutting with chamfered and blunt tools
,”
ASME Journal of Manufacturing Science and Engineering
,
124
,
178
–
188
.
21.
Adibi-Sedeh, A.H., and Madhavan, V., 2003, “Understanding of finite element analysis results under the framework of Oxley’s machining model,” Proceedings of the 6th CIRP International Workshop on Modeling of Machining Operations, Hamilton, Canada.
22.
Haglund
A. J.
,
Kishawy
H. A.
and
Rogers
R. J.
, “
On Friction Modeling in Orthogonal Machining: An Arbitrary Lagrangian-Eulerian Finite Element Model
,”
Transactions of NAMRI/SME
,
33
,
589
–
596
.
23.
O¨zel, T. and Zeren, E., 2005, “Finite element method simulation of machining of AISI 1045 steel with a round edge cutting tool,” Proceedings of the 8th CIRP International Workshop on Modeling of Machining Operations, Chemnitz, Germany, 533–542.
24.
O¨zel
T.
,
2003
, “
Modeling of Hard Part Machining: Effect of Insert Edge Preparation for CBN Cutting Tools
,”
Journal of Materials Processing Technology
,
141
,
284
–
293
.
25.
Yen
Y-C.
,
Jain
A.
and
Altan
T.
,
2004
, “
A finite element analysis of orthogonal machining using different toll edge geometries
,”
Journal of Materials Processing Technology
,
146
/
1
,
72
–
81
.
26.
Chuzhoy
L.
,
DeVor
R. E.
and
Kapoor
S. G.
,
2003
, “
Machining Simulation of Ductile Iron and Its Constituents. Part 2: Numerical Simulation and Experimental Validation of Machining
,”
ASME Journal of Manufacturing Science and Engineering
,
125
,
192
–
201
.
27.
Yang
X.
and
Liu
C. R.
,
2002
, “
A new stress-based model of friction behavior in machining and its significant impact on residual stresses computed by finite element method
,”
International Journal of Mechanical Sciences
,
44
/
4
,
703
–
723
.
28.
Liu
C. R.
and
Guo
Y. B.
,
2000
, “
Finite element analysis of the effect of sequential cuts and tool-chip friction on residual stresses in a machined layer
,”
Int. J. Mech. Sci.
,
42
,
1069
–
1086
.
29.
Guo
Y. B.
and
Liu
C. R.
,
2002
, “
3D FEA Modeling of Hard Turning
,”
ASME Journal of Manufacturing Science and Engineering
,
124
,
189
–
199
.
30.
Guo
Y. B.
and
Wen
Q
,
2005
, “
A Hybrid Modeling Approach to Investigate Chip Morphology Transition with The Stagnation Effect by Cutting Edge Geometry
,”
Transactions of NAMRI/SME
,
33
,
469
–
476
.
31.
Davies
M. A.
,
Cao
Q.
,
Cooke
A. L.
and
Ivester
R.
,
2003
, “
On the measurement and prediction of temperature fields in machining of AISI 1045 steel
,”
Annals of the CIRP
,
52
/
1
,
77
–
80
.
32.
Deshayes, L., Ivester, R., Mabrrouki, T., and Rigal, J-F, 2004, “Serrated chip morphology and comparison with Finite Element simulations,” Proceedings of IMECE 2004, November 13–20, 2004, Anaheim, California, USA.
33.
Johnson, G.R. and W.H. Cook, 1983, “A constitutive model and data for metals subjected to large strains, high strain rates and high temperatures,” Proceedings of the 7th International Symposium on Ballistics, The Hague, The Netherlands, 541–547.
34.
Jaspers
S. P. F. C
and
Dautzenberg
J. H.
,
2002
, “
Material behavior in conditions similar to metal cutting: flow stress in the primary shear zone
,”
Journal of Materials Processing Technology
,
122
,
322
–
330
.
35.
Ng
E.-G.
,
Tahany
I. E. W.
,
Dumitrescu
M.
, and
Elbastawi
M. A.
,
2002
, “
Physics-based simulation of high speed machining
,”
Machining Science and Technology
,
6
/
3
,
301
–
329
.
36.
Meyer
H. W.
. and
Kleponis
D. S.
,
2001
, “
Modeling the high strain rate behavior of titanium undergoing ballistic impact and penetration
,”
International Journal of Impact Engineering
,
26
,
509
–
521
.
37.
O¨zel, T. and Zeren, E., 2004, “A Methodology to Determine Work Material Flow Stress and Tool-Chip Interfacial Friction Properties by Using Analysis of Machining,” Proceedings of IMECE’04, November 13–19, 2004, Anaheim, California, USA.
This content is only available via PDF.
Copyright © 2005
 by ASME
You do not currently have access to this content.