Predicting periodic evolution of BUE formation mechanisms during machining ductile material using damage mechanics

Built-up edge (BUE) formation in machining maintains a profound effect on the cutting operation, such as cutting forces, cutting temperatures, tool wear, tool life, cutting vibration, surface roughness and the geometric dimensions of machined products and so on. Recently, attempts have been made to...

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Autores principales:	Xiaoqi SONG, Weiming HE, Tohru IHARA
Formato:	article
Lenguaje:	EN
Publicado:	The Japan Society of Mechanical Engineers 2016
Materias:	bue adhesion quasi-equilibrium thermal effects damage mechanics Mechanical engineering and machinery TJ1-1570
Acceso en línea:	https://doaj.org/article/d01ecea06bcf4c238ed198d293fbc866
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spelling	oai:doaj.org-article:d01ecea06bcf4c238ed198d293fbc8662021-11-26T06:58:33ZPredicting periodic evolution of BUE formation mechanisms during machining ductile material using damage mechanics2187-974510.1299/mej.15-00534https://doaj.org/article/d01ecea06bcf4c238ed198d293fbc8662016-11-01T00:00:00Zhttps://www.jstage.jst.go.jp/article/mej/3/6/3_15-00534/_pdf/-char/enhttps://doaj.org/toc/2187-9745Built-up edge (BUE) formation in machining maintains a profound effect on the cutting operation, such as cutting forces, cutting temperatures, tool wear, tool life, cutting vibration, surface roughness and the geometric dimensions of machined products and so on. Recently, attempts have been made to use BUE as the tool cutting edge/wedge to optimize machining, extend the tool life, etc. In order to have a clearly understanding of BUE formation, cutting experiments were performed on aluminum alloy A6063-T5 and low carbon steel STKM11A using the cemented carbide tool over a wide range of cutting speeds. The cutting speed of BUE formation spans just a small range of the cutting speed under low cutting speed and disappears with increasing the cutting speed, which is found to be ascribed to the decrease of cutting force and thermal effects that caused by increasing cutting speed. Further microscopic observations reveal that the temperature, plastic shear and shear rate in secondary shear zone are significantly related to BUE formation, which increases with increasing the cutting speed. Since the chip thickness ratio is an important parameter to characterize the chip plastic deformation, the relationship between the chip thickness ratio and BUE formation is considered. In this work, a new theoretical damage model is developed to predict the evolution of BUE formation, in which the reduction of material properties due to the thermal effects had been considered. And the model validation is performed by comparing the experimental results with the simulations for aluminum alloy A6063-T6 and low carbon steel STKM-11A, which clearly shows that the proposed analytical BUE formation model is able to predict the periodic evolution of BUE formation. Not only the cycle time can be predicted, but also it makes a more clearly understanding of the evolution of BUE formation mechanism and its effects.Xiaoqi SONGWeiming HETohru IHARAThe Japan Society of Mechanical Engineersarticlebueadhesionquasi-equilibriumthermal effectsdamage mechanicsMechanical engineering and machineryTJ1-1570ENMechanical Engineering Journal, Vol 3, Iss 6, Pp 15-00534-15-00534 (2016)
institution	DOAJ
collection	DOAJ
language	EN
topic	bue adhesion quasi-equilibrium thermal effects damage mechanics Mechanical engineering and machinery TJ1-1570
spellingShingle	bue adhesion quasi-equilibrium thermal effects damage mechanics Mechanical engineering and machinery TJ1-1570 Xiaoqi SONG Weiming HE Tohru IHARA Predicting periodic evolution of BUE formation mechanisms during machining ductile material using damage mechanics
description	Built-up edge (BUE) formation in machining maintains a profound effect on the cutting operation, such as cutting forces, cutting temperatures, tool wear, tool life, cutting vibration, surface roughness and the geometric dimensions of machined products and so on. Recently, attempts have been made to use BUE as the tool cutting edge/wedge to optimize machining, extend the tool life, etc. In order to have a clearly understanding of BUE formation, cutting experiments were performed on aluminum alloy A6063-T5 and low carbon steel STKM11A using the cemented carbide tool over a wide range of cutting speeds. The cutting speed of BUE formation spans just a small range of the cutting speed under low cutting speed and disappears with increasing the cutting speed, which is found to be ascribed to the decrease of cutting force and thermal effects that caused by increasing cutting speed. Further microscopic observations reveal that the temperature, plastic shear and shear rate in secondary shear zone are significantly related to BUE formation, which increases with increasing the cutting speed. Since the chip thickness ratio is an important parameter to characterize the chip plastic deformation, the relationship between the chip thickness ratio and BUE formation is considered. In this work, a new theoretical damage model is developed to predict the evolution of BUE formation, in which the reduction of material properties due to the thermal effects had been considered. And the model validation is performed by comparing the experimental results with the simulations for aluminum alloy A6063-T6 and low carbon steel STKM-11A, which clearly shows that the proposed analytical BUE formation model is able to predict the periodic evolution of BUE formation. Not only the cycle time can be predicted, but also it makes a more clearly understanding of the evolution of BUE formation mechanism and its effects.
format	article
author	Xiaoqi SONG Weiming HE Tohru IHARA
author_facet	Xiaoqi SONG Weiming HE Tohru IHARA
author_sort	Xiaoqi SONG
title	Predicting periodic evolution of BUE formation mechanisms during machining ductile material using damage mechanics
title_short	Predicting periodic evolution of BUE formation mechanisms during machining ductile material using damage mechanics
title_full	Predicting periodic evolution of BUE formation mechanisms during machining ductile material using damage mechanics
title_fullStr	Predicting periodic evolution of BUE formation mechanisms during machining ductile material using damage mechanics
title_full_unstemmed	Predicting periodic evolution of BUE formation mechanisms during machining ductile material using damage mechanics
title_sort	predicting periodic evolution of bue formation mechanisms during machining ductile material using damage mechanics
publisher	The Japan Society of Mechanical Engineers
publishDate	2016
url	https://doaj.org/article/d01ecea06bcf4c238ed198d293fbc866
work_keys_str_mv	AT xiaoqisong predictingperiodicevolutionofbueformationmechanismsduringmachiningductilematerialusingdamagemechanics AT weiminghe predictingperiodicevolutionofbueformationmechanismsduringmachiningductilematerialusingdamagemechanics AT tohruihara predictingperiodicevolutionofbueformationmechanismsduringmachiningductilematerialusingdamagemechanics
_version_	1718409745683972096

Predicting periodic evolution of BUE formation mechanisms during machining ductile material using damage mechanics

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