Authors: Ashwin Devotta; Tomas Beno; Ronnie Löf
Addresses: R&D Turning, Sandvik Coromant, SE-81181 Sandviken, Sweden ' University West, PTC, Byggnad 73, SE-46153 Trollhättan, Sweden ' R&D Turning, Sandvik Coromant, SE-81181 Sandviken, Sweden
Abstract: Finite element (FE) modelling of machining provide valuable insights into its deformation mechanics. Evaluating an FE model predicted chip morphology requires characterisation of chip shape, chip curl and chip flow angles. In this study, a chip morphology characterisation methodology is developed using computed tomography (CT), high-speed imaging and Kharkevich model equations enabling evaluation of FE model's chip morphology prediction accuracy. Chip formation process in nose turning of AISI 1045 steel is simulated using a 3D FE model for varying feed rate and depth of cut and evaluated against experimental investigations using the employed methodology. The study shows that the methodology is able to characterise chip morphology in nose turning process accurately and enables evaluation of FE model's chip morphology prediction accuracy. This can enable the finite element model to be deployed in cutting tool design for chip breaker geometry design.
Keywords: machining; chip-up-curl; chip-side-curl; chip shape; computed tomography; CT; finite element model; chip side flow angle; Johnson cook model; coulomb friction model; advantedge; high speed videography.
International Journal of Machining and Machinability of Materials, 2017 Vol.19 No.3, pp.277 - 295
Received: 07 Nov 2015
Accepted: 22 May 2016
Published online: 02 May 2017 *