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Predicting Continuous Chip to Segmented Chip Transition in Orthogonal Cutting of C45E Steel through Damage Modeling
Sandvik Coromant AB, R&D Turning, S-81181 Sandviken, Sweden.ORCID iD: 0000-0003-3877-9067
Sandvik Mat Technol AB, R&D, S-81181 Sandviken, Sweden.
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. (PTW)ORCID iD: 0000-0003-0976-9820
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. (PTW)ORCID iD: 0000-0001-9331-7354
2020 (English)In: Metals, ISSN 2075-4701, Vol. 10, no 4, article id 519Article in journal (Refereed) Published
Abstract [en]

Machining process modeling has been an active endeavor for more than a century and it has been reported to be able to predict industrially relevant process outcomes. Recent advances in the fundamental understanding of material behavior and material modeling aids in improving the sustainability of industrial machining process. In this work, the flow stress behavior of C45E steel is modeled by modifying the well-known Johnson-Cook model that incorporates the dynamic strain aging (DSA) influence. The modification is based on the Voyiadjis-Abed-Rusinek (VAR) material model approach. The modified JC model provides the possibility for the first time to include DSA influence in chip formation simulations. The transition from continuous to segmented chip for varying rake angle and feed at constant cutting velocity is predicted while using the ductile damage modeling approach with two different fracture initiation strain models (Autenrieth fracture initiation strain model and Karp fracture initiation strain model). The result shows that chip segmentation intensity and frequency is sensitive to fracture initiation strain models. The Autenrieth fracture initiation strain model can predict the transition from continuous to segmented chip qualitatively. The study shows the transition from continuous chip to segmented chip for varying feed rates and rake angles for the first time. The study highlights the need for material testing at strain, strain rate, and temperature prevalent in the machining process for the development of flow stress and fracture models.

Place, publisher, year, edition, pages
MDPI, 2020. Vol. 10, no 4, article id 519
Keywords [en]
chip segmentation; damage modeling; dynamic strain aging
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology
Identifiers
URN: urn:nbn:se:hv:diva-15788DOI: 10.3390/met10040519ISI: 000531826500098Scopus ID: 2-s2.0-85083847260OAI: oai:DiVA.org:hv-15788DiVA, id: diva2:1466809
Funder
Knowledge Foundation, 20110263, 20140130Available from: 2020-09-14 Created: 2020-09-14 Last updated: 2021-02-11

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Devotta, Ashwin MorisBeno, TomasEynian, Mahdi

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