Multistep hybrid approach applied to material removal operation using cutting tool
Résumé
Cutting processes are widely used in different industries to cut different engineering parts. Usually the optimization of these processes is made by experimental or numerical simulations but the major inconvenience of those methods is the cost and the time needed. For all these reasons, in manufacturing industry, a highly interest in analytical methods are usually researched because there are very practice to use but those methods don’t take into account all the aspects of the contact between the work material and the tool. In particular ploughing and spring back are usually not considered, what is pertinent for small cutting radius but not for bigger ones (used tools). In this paper en hybrid approach is presented. Both analytical and numerical approaches are used in order to model and understand physic during removal processes. In particular a multi-steps model for orthogonal cutting has been developed in order to study the influence of the cumulated strain and temperature induced by the different steps on the residual stresses. The effect of tool edge radius and heat generated by flank friction on the predicted stress profile is analytically modelled. In fact, in the case of most of industrial processes, like turning, milling, grinding, the cutting tool is in contact with a part of material that was the finished piece in the previous step Commercial finite element software ABAQUS with its Explicit and Implicit modules was used. Computed Numerical predicted stress fields are compared against measured residual stresses obtained by X-Ray diffraction. Moreover, in order to take into account all the physics in the tool-work material interface, spring-back simulation was performed using both ABAQUS Explicit and ABAQUS Implicit.
Domaines
Mécanique [physics]Origine | Fichiers éditeurs autorisés sur une archive ouverte |
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