Determination of thermal material properties for the numerical simulation of cutting processes

Thermal properties of machined materials, which depend significantly on the change in cutting temperature, have a considerable effect on thermal machining characteristics. Therefore, the thermal properties used for the numerical simulation of the cutting process should be determined depending on the...

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Bibliographic Details
Published in:International journal of advanced manufacturing technology 2022, Vol.118 (5-6), p.1941-1956
Main Authors: Storchak, Michael, Stehle, Thomas, Möhring, Hans-Christian
Format: Article
Language:English
Subjects:
Algorithms
CAE) and Design
Computer simulation
Computer-Aided Engineering (CAD
Constitutive equations
Constitutive relationships
Engineering
High strength steels
Industrial and Production Engineering
Machine tools
Machining
Material properties
Mathematical models
Mechanical Engineering
Media Management
Original Article
Temperature
Thermal conductivity
Thermodynamic properties
Thrust
Titanium alloys
Titanium base alloys
Yield stress
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Summary:Thermal properties of machined materials, which depend significantly on the change in cutting temperature, have a considerable effect on thermal machining characteristics. Therefore, the thermal properties used for the numerical simulation of the cutting process should be determined depending on the cutting temperature. To determine the thermal properties of the machined materials, a methodology and a software-implemented algorithm were developed for their calculation. This methodology is based on analytical models for the determination of tangential stress in the primary cutting zone. Based on this stress and experimentally or analytically determined cutting temperatures, thermal properties of the machined material were calculated, namely the coefficient of the heat capacity as well as the coefficient of thermal conductivity. Three variants were provided for determining the tangential stress: based on the yield stress calculated using the Johnson-Cook constitutive equation, based on the experimentally determined cutting and thrust forces as well as by directly calculating the tangential stress. The thermal properties were determined using the example of three different materials: AISI 1045 and AISI 4140 steel as well as Ti10V2Fe3Al titanium alloy (Ti-1023). With the developed FE cutting model, the deviation between experimental and simulated temperature values ranged from approx. 7.5 to 14.4%.
ISSN:0268-3768
1433-3015
DOI:10.1007/s00170-021-08021-2