Modeling of Production Metal Cutting Processes
Troy Marusich
Third Wave Systems Inc., Minneapolis, MN
Thursday, April 18, 2002 13:00-14:00,
Employee Lounge, NIST Administration Building
Gaithersburg
Abstract:
In order to improve metal cutting processes by lowering part cost
and improving quality, it is necessary to model metal cutting processes
at a system level. A necessary requirement is the ability to model
interactions at the tool-chip interface, and thus predict cutter
performance. A methodology is presented to model performance of cutting
tools using an orthogonal, plane strain, and three-dimensional finite
element (FE) software program called AdvantEdge. Theoretical
underpinnings of the tightly coupled thermo-mechanical Lagrangian model
are described, such as constitutive modeling for high strain rates,
large deformations, and near-melt
temperatures; fully adaptive mesh generation in two and
three-dimensions; and deformable tool-workpiece contact with friction
and interfacial heat transfer. The compilation of these numerical
techniques allows modeling of plane strain orthogonal machining in two
dimensions, and oblique cutting, nose turning, and milling in three
dimensions. Model validation procedures are detailed, and comparison
with experimental data, including cutting forces, chip thickness, curl
and breakage, and chip morphology (e.g., shear localized, continuous).
Several application examples are provided, such as chip breakage, forced
and free tool vibration, machining induced workpiece residual stress
analysis, three-dimensional oblique cutting, and nose turning. Finally,
a system-level mechanistic machining model is briefly described for
turning, milling, and drilling, and a symbiotic relationship with the FE
capability is shown.
Contact: T. J. BurnsNote: Visitors from outside NIST must contact
Robin Bickel; (301) 975-3668;
at least 24 hours in advance.
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