A physical-based constitutive model for surface integrity prediction in machining of OFHC copper

Due to the rising interest in predicting machined surface integrity and sustainability, various models for metal cutting simulation have been developed. However, their accuracy depends deeply on the physical description of the machining process. This study aims to develop an orthogonal cutting model...

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Bibliographic Details
Published in:Journal of materials processing technology 2017-10, Vol.248 (octobre), p.143-160
Main Authors: Denguir, L.A., Outeiro, J.C., Fromentin, G., Vignal, V., Besnard, R.
Format: Article
Language:English
Subjects:
Computer simulation
Constitutive model
Copper
Cutting parameters
Dislocation density
Engineering Sciences
Finite element method
Grain size
Integrity
Machine tools
Machining
Materials
Mathematical models
Mechanical engineering
Mechanical tests
Mechanics
Mechanics of materials
Metal cutting
Microstructure
Modelling
OFHC copper
Orthogonal cutting
Predictions
Residual stress
Surface integrity
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Summary:Due to the rising interest in predicting machined surface integrity and sustainability, various models for metal cutting simulation have been developed. However, their accuracy depends deeply on the physical description of the machining process. This study aims to develop an orthogonal cutting model for surface integrity prediction, which includes a physical-based constitutive model of Oxygen Free High Conductivity (OFHC) copper. This constitutive model incorporates the effects of the state of stress and microstructure on the work material behavior, as well as a dislocation density-based model for surface integrity prediction. The coefficients of the constitutive model were identified through a hybrid experimental/numerical approach, consisting in mechanical tests, numerical simulations and an optimization-based algorithm. The orthogonal cutting model was simulated by FEM, using ALE formulation, and was validated by comparing predicted and measured results, including residual stresses, dislocation density and grain size. The model is then used to analyze the influence of the cutting parameters and cutting geometry on surface integrity, and its results are compared to those obtained by the Johnson-Cook model.
ISSN:0924-0136
1873-4774
DOI:10.1016/j.jmatprotec.2017.05.009