Title: The investigation of effects of friction on the formation of dead metal zone with finite element method

Authors: Lei Wan; Dazhong Wang; Shujing Wu

Addresses: Shanghai University of Engineering Science, Shanghai 201620, China ' Shanghai University of Engineering Science, Shanghai 201620, China ' Shanghai University of Engineering Science, Shanghai 201620, China

Abstract: A fundamental and quantitative analysis of the effect of the tool-chip friction on the formation of dead metal zone (DMZ) helps to better understand the mechanism of DMZ formation and other complex phenomena in machining, including the distributions of stress, strain and temperature as well as the forces, with a chamfer tool. Three different friction cases were implemented in the FE software ABAQUS/Explicit and the simulated results were obtained. An attempt has been made in this paper to explore and evaluate various friction conditions used in numerical simulations of cutting machining. An ALE approach-based finite element model was developed for the simulation of orthogonal machining and utilised to study the friction conditions prevailing at the chip-tool interface for ductile steel. The simulated results, for a wide range of different friction conditions, were obtained and compared to previously published experimental findings. Currently, the ALE approach is common in metal machining simulation because it does not need any chip separation criteria to enable initial chip shape to a reasonable one smoothly, while maintaining perfect meshing properties, which make it much more useful than Lagrange and Euler approaches.

Keywords: dead metal zone; DMZ; coefficient of friction; COF; finite element method; FEM.

DOI: 10.1504/IJIMS.2016.084543

International Journal of Internet Manufacturing and Services, 2016 Vol.4 No.2, pp.118 - 133

Received: 06 Oct 2016
Accepted: 24 Nov 2016
Published online: 13 Jun 2017 *

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