A Numerical-Experimental Study on Orthogonal Cutting of AISI 1045 Steel and Ti6Al4V Alloy: SPH and FEM Modeling with Newly Identified Friction Coefficients

Numerical simulation of metal cutting with rigorous experimental validation is a profitable approach that facilitates process optimization and better productivity. In this work, we apply the Smoothed Particle Hydrodynamics (SPH) and Finite Element Method (FEM) to simulate the chip formation process...

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Autores principales:	Mohamadreza Afrasiabi, Jannis Saelzer, Sebastian Berger, Ivan Iovkov, Hagen Klippel, Matthias Röthlin, Andreas Zabel, Dirk Biermann, Konrad Wegener
Formato:	article
Lenguaje:	EN
Publicado:	MDPI AG 2021
Materias:	metal cutting force temperature friction simulation FEM Mining engineering. Metallurgy TN1-997
Acceso en línea:	https://doaj.org/article/8ce121abca3e4dfea441431e36b56fb3
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spelling	oai:doaj.org-article:8ce121abca3e4dfea441431e36b56fb32021-11-25T18:21:11ZA Numerical-Experimental Study on Orthogonal Cutting of AISI 1045 Steel and Ti6Al4V Alloy: SPH and FEM Modeling with Newly Identified Friction Coefficients10.3390/met111116832075-4701https://doaj.org/article/8ce121abca3e4dfea441431e36b56fb32021-10-01T00:00:00Zhttps://www.mdpi.com/2075-4701/11/11/1683https://doaj.org/toc/2075-4701Numerical simulation of metal cutting with rigorous experimental validation is a profitable approach that facilitates process optimization and better productivity. In this work, we apply the Smoothed Particle Hydrodynamics (SPH) and Finite Element Method (FEM) to simulate the chip formation process within a thermo-mechanically coupled framework. A series of cutting experiments on two widely-used workpiece materials, i.e., AISI 1045 steel and Ti6Al4V titanium alloy, is conducted for validation purposes. Furthermore, we present a novel technique to measure the rake face temperature without manipulating the chip flow within the experimental framework, which offers a new quality of the experimental validation of thermal loads in orthogonal metal cutting. All material parameters and friction coefficients are identified in-situ, proposing new values for temperature-dependent and velocity-dependent friction coefficients of AISI 1045 and Ti6Al4V under the cutting conditions. Simulation results show that the choice of friction coefficient has a higher impact on SPH forces than FEM. Average errors of force prediction for SPH and FEM were in the range of 33% and 23%, respectively. Except for the rake face temperature of Ti6Al4V, both SPH and FEM provide accurate predictions of thermal loads with 5–20% error.Mohamadreza AfrasiabiJannis SaelzerSebastian BergerIvan IovkovHagen KlippelMatthias RöthlinAndreas ZabelDirk BiermannKonrad WegenerMDPI AGarticlemetal cuttingforcetemperaturefrictionsimulationFEMMining engineering. MetallurgyTN1-997ENMetals, Vol 11, Iss 1683, p 1683 (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	metal cutting force temperature friction simulation FEM Mining engineering. Metallurgy TN1-997
spellingShingle	metal cutting force temperature friction simulation FEM Mining engineering. Metallurgy TN1-997 Mohamadreza Afrasiabi Jannis Saelzer Sebastian Berger Ivan Iovkov Hagen Klippel Matthias Röthlin Andreas Zabel Dirk Biermann Konrad Wegener A Numerical-Experimental Study on Orthogonal Cutting of AISI 1045 Steel and Ti6Al4V Alloy: SPH and FEM Modeling with Newly Identified Friction Coefficients
description	Numerical simulation of metal cutting with rigorous experimental validation is a profitable approach that facilitates process optimization and better productivity. In this work, we apply the Smoothed Particle Hydrodynamics (SPH) and Finite Element Method (FEM) to simulate the chip formation process within a thermo-mechanically coupled framework. A series of cutting experiments on two widely-used workpiece materials, i.e., AISI 1045 steel and Ti6Al4V titanium alloy, is conducted for validation purposes. Furthermore, we present a novel technique to measure the rake face temperature without manipulating the chip flow within the experimental framework, which offers a new quality of the experimental validation of thermal loads in orthogonal metal cutting. All material parameters and friction coefficients are identified in-situ, proposing new values for temperature-dependent and velocity-dependent friction coefficients of AISI 1045 and Ti6Al4V under the cutting conditions. Simulation results show that the choice of friction coefficient has a higher impact on SPH forces than FEM. Average errors of force prediction for SPH and FEM were in the range of 33% and 23%, respectively. Except for the rake face temperature of Ti6Al4V, both SPH and FEM provide accurate predictions of thermal loads with 5–20% error.
format	article
author	Mohamadreza Afrasiabi Jannis Saelzer Sebastian Berger Ivan Iovkov Hagen Klippel Matthias Röthlin Andreas Zabel Dirk Biermann Konrad Wegener
author_facet	Mohamadreza Afrasiabi Jannis Saelzer Sebastian Berger Ivan Iovkov Hagen Klippel Matthias Röthlin Andreas Zabel Dirk Biermann Konrad Wegener
author_sort	Mohamadreza Afrasiabi
title	A Numerical-Experimental Study on Orthogonal Cutting of AISI 1045 Steel and Ti6Al4V Alloy: SPH and FEM Modeling with Newly Identified Friction Coefficients
title_short	A Numerical-Experimental Study on Orthogonal Cutting of AISI 1045 Steel and Ti6Al4V Alloy: SPH and FEM Modeling with Newly Identified Friction Coefficients
title_full	A Numerical-Experimental Study on Orthogonal Cutting of AISI 1045 Steel and Ti6Al4V Alloy: SPH and FEM Modeling with Newly Identified Friction Coefficients
title_fullStr	A Numerical-Experimental Study on Orthogonal Cutting of AISI 1045 Steel and Ti6Al4V Alloy: SPH and FEM Modeling with Newly Identified Friction Coefficients
title_full_unstemmed	A Numerical-Experimental Study on Orthogonal Cutting of AISI 1045 Steel and Ti6Al4V Alloy: SPH and FEM Modeling with Newly Identified Friction Coefficients
title_sort	numerical-experimental study on orthogonal cutting of aisi 1045 steel and ti6al4v alloy: sph and fem modeling with newly identified friction coefficients
publisher	MDPI AG
publishDate	2021
url	https://doaj.org/article/8ce121abca3e4dfea441431e36b56fb3
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A Numerical-Experimental Study on Orthogonal Cutting of AISI 1045 Steel and Ti6Al4V Alloy: SPH and FEM Modeling with Newly Identified Friction Coefficients

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