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An experimental and finite element investigation of chip separation criteria in metal cutting process

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Abstract

Chip separation is an important issue in finite element method (FEM)-based simulation of the cutting process owing to its significant impact on the predicted chip formation, as well as on the temperature and stress distributions. Typically, the chip separation criteria and the arbitrary Lagrangian–Eulerian (ALE) method have been utilized in chip formation simulations. This study aimed to evaluate the chip separation criterion and the ALE method in terms of chip formation, cutting force, cutting temperature, and stress distribution. Particularly, the effective plastic strain criterion and the failure-zone-assisted and ALE methods were utilized to model the orthogonal cutting of Inconel 718 alloy. Furthermore, experimentations were performed, and the results of FEM predictions were compared with the experimentally measured results. In general, ALE method was more consistent with the experiment. The ESPC method does not seem to handle chip shape and cutting temperature well, while the FZA method may not be suitable for predicting surface stress due to the deformation and failure of the material concentrated in the fail assist area.

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Abbreviations

FE:

finite element

\( \overset{\frown }{\theta } \) :

nondimensional temperature

D 1~D 5 :

material-dependent fracture constants

\( \Delta {\overline{\varepsilon}}^{pl} \) :

equivalent plastic strain increment

\( {{\overline{\varepsilon}}_0}^{pl} \) :

initial equivalent plastic strain

v f :

feed rate (mm/rev)

doc :

depth of cut (mm)

h :

equivalent undeformed chip height

l′ :

equivalent undeformed chip length

σ :

flow stress

ε pl :

equivalent plastic strain

ε 0 :

strain rate parameter

ε pl :

equivalent plastic strain rate

ε f pl :

Equivalent failure plastic strain

ε el :

elastic strain

η ∞ :

η at infinite sliding velocity

η 0 :

η at low sliding velocity

η:

non-plastic heat generation rate

γ :

sensitivity to the sliding velocity

q :

sensitivity to the temperature

k:

heat conduction coefficient

\( \partial {\overline{\varepsilon}}^{pl} \) :

effective plastic strain increment

v c :

cutting speed

θ :

current temperature

θ t :

transition temperature

θ m :

melting temperature

A :

JC material parameters

B :

JC material parameters

C :

JC material parameters

n :

JC material parameters

m :

JC material parameters

\( {\overrightarrow{F}}_T \) :

tangential force

\( {\overrightarrow{F}}_N \) :

normal force

η :

friction coefficient

\( \overset{\frown }{T} \) :

temperature parameter

η :

friction coefficient

D 1 ~D 5 :

failure parameters

k :

shear friction factor

ρ :

density (g/mm3)

ΔT :

temperature increment

ρ :

density (g/mm3)

\( \overline{\sigma} \) :

effective stress

C p :

specific heat

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Funding

This work is supported by the National Natural Science Foundation of China (no. 50935001), the Important National Science & Technology Specific Projects (2009ZX04014-041), and the National Basic Research Program of China (2010CB731703).

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Authors and Affiliations

  1. School of Mechanical Engineering, Shanghai University of Engineering Science, Shanghai, 201620, People’s Republic of China

    Junli Li, Ziru Huang & Gang Liu

  2. School of Mechanical Engineering, Shanghai Jiao Tong University, Shanghai, 200240, People’s Republic of China

    Qinglong An & Ming Chen

Authors
  1. Junli Li
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  2. Ziru Huang
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  3. Gang Liu
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  4. Qinglong An
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  5. Ming Chen
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Contributions

Dr. Li determined the research method and experimental scheme of the paper, completed most of the finite element simulation works, and completed the writing of the paper. Master student Huang was responsible for most of the cutting experiments. Professor Liu guided the finite element simulation work of this paper. Dr. An mainly participated in the cutting simulation work of this paper, and Professor Chen provided the funding and platform for the research work of this paper.

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Correspondence to Gang Liu.

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Li, J., Huang, Z., Liu, G. et al. An experimental and finite element investigation of chip separation criteria in metal cutting process. Int J Adv Manuf Technol 116, 3877–3889 (2021). https://doi.org/10.1007/s00170-021-07461-0

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  • DOI: https://doi.org/10.1007/s00170-021-07461-0

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