Hits:

Indexed by:期刊论文

Date of Publication:2013-02-01

Journal:INTERNATIONAL JOURNAL OF ADVANCED MANUFACTURING TECHNOLOGY

Included Journals:SCIE、EI、Scopus

Volume:64

Issue:9-12

Page Number:1587-1597

ISSN No.:0268-3768

Key Words:High-speed cutting (HSC); Finite element simulation; Serrated chip; Chip separation criterion; Friction

Abstract:Serrated chip formation influences almost every aspect of a high-speed cutting (HSC) process. This paper aims to develop a reliable method to accurately predict such chip formation processes. To this end, a systematic finite element analysis was carried out and a series of HSC experiments were conducted on a heat treated AISI 1045 steel. It was found that the integrative use of the Johnson-Cook thermal-viscoplastic constitutive equation, Johnson-Cook damage criterion for chip separation, and the modified Zorev's friction model can precisely predict the serrated chip formation in HSC without artificial assumptions. This advancement has removed the major barrier in the current machining investigations by numerical simulation. The present study also found that the tool rake angle has a significant effect on serrated chip formation. As the rake angle increases, the chip sawtooth degree and cutting forces decrease, but the chip segmentation frequency increases.