Skip to main content
SpringerLink
Log in

Effect of rake angle on Johnson-Cook material constants and their impact on cutting process parameters of Al2024-T3 alloy machining simulation

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Finite element modeling (FEM) of machining has recently become the most attractive computational tool to predict and optimize metal cutting processes. High-speed computers and advanced finite element code have offered the possibility of simulating complex machining processes such as turning, milling, and drilling. The use of an accurate constitutive law is very important in any metal cutting simulation. It is desirable that a constitutive law could completely characterize the thermo-visco-plastic behavior of the machined materials at high strain rate. The most commonly used law is that of Johnson and Cook (JC) which combines the effect of strains, strain rates, and temperatures. Unfortunately, the different coefficients provided in the literature for a given material are not reliable since they affect significantly the predicted results (cutting forces, temperatures, residual stresses, etc.). In the present work, five different sets of JC are determined based on orthogonal machining tests. These five sets are then used in finite element modeling to simulate the machining behavior of Al2024-T3 alloy. The effects of these five different sets of JC constants on the numerically predicted cutting forces, chip morphology, and tool-chip contact length are the subject of a comparative investigation. It is concluded that these predicted cutting parameters are sensitive to the material constants.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. Gonzalo O, Jauregi H, Uriarte L, de Lacalle LL (2009) Prediction of specific force coefficients from a FEM cutting model. Int J Adv Manuf Technol 43:348–356

    Article  Google Scholar 

  2. Davim JP, Maranhao C, Jackson M, Cabral G, Gracio J (2008) FEM analysis in high speed machining of aluminium alloy (Al7075-0) using polycrystalline diamond (PCD) and cemented carbide (K10) cutting tools. Int J Adv Manuf Technol 39:1093–1100

    Article  Google Scholar 

  3. Seshadri R, Naveen I, Srinivasan S, Viswasubrahmanyam M, VijaySekar K, Pradeep Kumar M (2013) Finite element simulation of the orthogonal machining process with Al 2024 T351 aerospace alloy. Procedia Eng 64:1454–1463

    Article  Google Scholar 

  4. Johnson GR, Cook WH (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 21 pp. 541–7

  5. Lesuer DR (2001) Experimental investigations of material models for Ti-6AL-4V titanium and 2024-T3 aluminium. Department of Transportation Federal Aviation Administration, USA

    Google Scholar 

  6. Rule WK (1997) A numerical scheme for extracting strength model coefficients from Taylor test data. Int J Impact Eng 19:797–810

    Article  Google Scholar 

  7. Sartkulvanich P, Altan T, Soehner J (2005) Flow stress data for finite element simulation in metal cutting: a progress report on madams. Mach Sci Technol 9:271–288

    Article  Google Scholar 

  8. Panov V (2006) Modelling of behaviour of metals at high strain rates. Cranfield University

  9. Yang JB, Wu WT, Srivatsa S (2011) Inverse flow stress calculation for machining processes. Adv Mater Res 223:267–276

    Article  Google Scholar 

  10. Tounsi N, Vincenti J, Otho A, Elbestawi M (2002) From the basic mechanics of orthogonal metal cutting toward the identification of the constitutive equation. Int J Mach Tools Manuf 42:1373–1383

    Article  Google Scholar 

  11. Shrot A, Bäker M (2012) Determination of Johnson–Cook parameters from machining simulations. Comput Mater Sci 52:298–304

    Article  Google Scholar 

  12. Guo Y (2003) An integral method to determine the mechanical behavior of materials in metal cutting. J Mater Process Technol 142:72–81

    Article  Google Scholar 

  13. Ozel T, breve, rul, Zeren E (2006) A methodology to determine work material flow stress and tool-chip interfacial friction properties by using analysis of machining, transaction-american society of mechanical engineers. J Manuf Sci Eng 128, pp. 119–129, 2006

  14. Limido J (2008) Étude de l’effet de l’usinage grande vitesse sur la tenue en fatigue de pièces aéronautiques. Université Toulouse III-Paul Sabatier, Toulouse

    Google Scholar 

  15. Filice L, Micari F, Rizzuti S, Umbrello D (2007) A critical analysis on the friction modelling in orthogonal machining. Int J Mach Tools Manuf 47:709–714

    Article  Google Scholar 

  16. Umbrello D, M’saoubi R, Outeiro J (2007) The influence of Johnson–Cook material constants on finite element simulation of machining of AISI 316L steel. Int J Mach Tools Manuf 47:462–470

    Article  Google Scholar 

  17. Daoud M, Jomaa W, Chatelain JF, Bouzid A (2014) A machining-based methodology to identify material constitutive law for finite element simulation. Int J Adv Manuf Technol 77:2019-2033

  18. Corporation SFT (2012) DEFORM 2D, V10.2, User’s manual. Columbus, OH, USA. pp. 760

  19. Ee K, Dillon O Jr, Jawahir I (2005) Finite element modeling of residual stresses in machining induced by cutting using a tool with finite edge radius. Int J Mech Sci 47:1611–1628

    Article  MATH  Google Scholar 

  20. Roy P, Sarangi S, Ghosh A, Chattopadhyay A (2009) Machinability study of pure aluminium and Al–12 % Si alloys against uncoated and coated carbide inserts. Int J Refract Met Hard Mater 27:535–544

    Article  Google Scholar 

  21. Cockcroft M, Latham D (1966) A simple criterion of fracture for ductile metals. National Engineering Laboratory

  22. ASM (1983) ASM metals reference book, 2nd edn. Metals Park, OH

    Google Scholar 

  23. Yen Y-C, Jain A, Chigurupati P, Wu W-T, Altan T (2004) Computer simulation of orthogonal cutting using a tool with multiple coatings. Mach Sci Technol 8:305–326

    Article  Google Scholar 

  24. Fang N (2005) A new quantitative sensitivity analysis of the flow stress of 18 engineering materials in machining. J Eng Mater Technol 127:192–196

    Article  Google Scholar 

  25. Klocke F, Lung D, Buchkremer S, Jawahir I (2013) From orthogonal cutting experiments towards easy-to-implement and accurate flow stress data. Mater Manuf Process 28:1222–1227

    Article  Google Scholar 

  26. Xie J, Bayoumi A, Zbib H (1996) A study on shear banding in chip formation of orthogonal machining. Int J Mach Tools Manuf 36:835–847

    Article  Google Scholar 

  27. Sartkulvanich P, Altan T, Göcmen A (2005) Effects of flow stress and friction models in finite element simulation of orthogonal cutting: a sensitivity analysis. Mach Sci Technol 9:1–26

    Article  Google Scholar 

  28. Nasr MN, Ng E-G, Elbestawi M (2007) Effects of strain hardening and initial yield strength on machining-induced residual stresses. J Eng Mater Technol 129:567–579

    Article  Google Scholar 

  29. Shi B, Attia H, Tounsi N (2010) Identification of material constitutive laws for machining. Part I: an analytical model describing the stress, strain, strain rate, and temperature fields in the primary shear zone in orthogonal metal cutting. ASME J Manuf Sci Eng 132(5):051008

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Mechanical Engineering, University of Quebec, ETS, 1100 Notre-Dame street West, Montreal, Quebec, Canada, H3C 1K3

    M. Daoud, J. F. Chatelain & A. Bouzid

Authors
  1. M. Daoud
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. J. F. Chatelain
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. A. Bouzid
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to M. Daoud.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Daoud, M., Chatelain, J.F. & Bouzid, A. Effect of rake angle on Johnson-Cook material constants and their impact on cutting process parameters of Al2024-T3 alloy machining simulation. Int J Adv Manuf Technol 81, 1987–1997 (2015). https://doi.org/10.1007/s00170-015-7179-y

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-015-7179-y

Keywords

Search

Navigation