Modeling the material mehavior under metal cutting conditions / Marvin Hardt.

Format:

Book

Author/Creator:

Hardt, Marvin, author.

Language:

English

Subjects (All):

Metal-cutting.

Physical Description:

1 online resource (204 pages)

Edition:

1st ed.

Place of Publication:

Aachen, Germany : Apprimus Verlag, [2022]

Summary:

The scientific goal of the present work was to model the workpiece material behavior of steels in the metal cutting process depending on the occurring thermo-mechanical loads. The results of this work shall make a significant contribution to the predictive process design of the cutting process by means of Finite Element (FE) simulations for the virtual representation of the reality in the sense of the digital twin.To achieve the objective, extensive empirical examinations were conducted in a first step, which included conventional material scientific and orthogonal cutting tests. This enabled the establishment of a database of the workpiece response with increasing thermo-mechanical loads. During the orthogonal cutting examinations, integral and locally resolved process results were measured, which were used as calibration and validation variables in the modeling of the workpiece material behavior.By extending an established friction test bench with a workpiece pre-heating system, the friction conditions between tool and workpiece could be investigated under conditions equivalent to the cutting process. Based on the experimental results, a friction model was derived, in which the observed effects of thermal softening and the localized adhesion-induced increase in the apparent friction coefficient were superposed. A phenomenological material model was developed to describe the workpiece material behavior in the cutting process. The formulation of the material mode was developed based on empirical examinations as well as results from the state of the art. The material model was implemented in an FE-chip formation simulation using a subroutine. A hybrid optimization algorithm was developed to inversely determine the material model parameters. By means of the optimization algorithm, the material model parameters could be systematically determined inversely, taking the experimentally determined process observables into account. An automated procedure linked to a user interface lowered the entry hurdle for industrial companies and unexperienced users of FE-simulations and reduced the computational effort for the inverse parameter determination to about 10 days of computational execution time. The quality of the developed models and the determined model parameters were further verified by a final deduction step using the industrial example of face turning.

Contents:

Intro

1 Introduction

2 State of the Art

2.1 The Orthogonal Cutting Process

2.2 Descriptive Cutting Models

2.2.1 Analytical Cutting Models

2.2.2 Numerical Cutting Models

2.3 Modeling the Friction Behavior in Metal Cutting Simulations

2.4 Material Models for Metal Cutting Simulations

2.4.1 Empirical and Phenomenological Material Models

2.4.2 Microstructure-Mechanical and Physical-Based Material Models

2.5 Methods for the Material Model Parameter Determination

2.5.1 Calibration from Quasi-Static and Dynamic Material Tests

2.5.2 Inverse Calibration from Cutting Examinations

2.5.3 Algorithm-Based Inverse Calibration

2.6 Interim Conclusions and Research Demand

3 Objective and Scientific Approach

4 Investigations on the Material Behavior of Steels

4.1 Material Scientific Characterization of the Workpiece Materials

4.2 Material Behavior under Quasi-Static Conditions

4.3 Material Toughness under Impact Conditions

4.4 Material Behavior under High Strain Rates Using SHPB-Tests

4.5 Material Behavior under Metal Cutting Conditions

4.5.1 Experimental Set-Up and Procedure of Orthogonal Cutting Examinations

4.5.2 Analysis of the Orthogonal Cutting Examinations

4.5.3 Experimental Set-Up and Procedure of Friction Examinations

4.5.4 Analysis of the Friction Examinations

4.6 Summary and Interim Conclusions

5 Material Model for Cutting Simulations

5.1 Constitutive Model of the Thermo-Mechanical Material Behavior

5.2 FE-Model of Orthogonal Cutting

5.3 Implementation of the Material Model in the FE-Simulation

5.4 Effect of the Material Model Parameters on Cutting Simulations

5.5 Summary and Interim Conclusions

6 Method for the Inverse Parameter Determination

6.1 Determining a Temperature-Dependent Friction Model.

6.2 Analysis of Process Observables from CEL-Simulations

6.3 Inverse Determination of Material Model Parameters

6.3.1 Inverse Parameter Determination Using the Downhill-Simplex-Algorithm

6.3.2 Inverse Parameter Determination using Particle-Swarm-Optimization

6.3.3 Hybrid Optimization Algorithm for the Inverse Parameter Determination

6.4 Inverse Determination and Validation of Material ModelParameters

6.5 Evaluation of the Computational Efficiency

6.6 Summary and Interim Conclusions

7 Validation of the Material Model for Face Turning

7.1 Experimental Set-Up and Results of Face Turning Examinations

7.2 Coupled EULERIAN-LAGRANGIAN Modeling of Face Turning

7.3 Validation of Face Turning Simulations

7.4 Summary and Interim Conclusions

8 Summary and Outlook

9 Appendix

9.1 Part A: Information on the Investigated Workpiece Materials

9.2 Part B: Experimental Results of Orthogonal Cutting

9.3 Part C: Further Information on the Material Model

9.4 Part D: Information on the Inverse Parameter Identification

9.5 Part E: GUI for the Inverse Parameter Determination

10 References

Résumé.

Notes:

Includes bibliographical references.

Description based on print version record.

Other Format:

Print version: Hardt, Marvin Modeling the Material Behavior under Metal Cutting Conditions

ISBN:

9783985550616