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This news article was originally written in Spanish. It has been automatically translated for your convenience. Reasonable efforts have been made to provide an accurate translation, however, no automated translation is perfect nor is it intended to replace a human translator. The original article in Spanish can be viewed at Simulación del corte de materiales dúctiles con herramientas de geometría definida
Machining

Simulation of the cutting of ductile materials with defined geometry tools

A. Celaya (1), i. Etxeberria (2), o. Gonzalo (2), J.L. Alcaraz (1), i. Lorenzo (1), L.N. Lopez de Lacalle (1)
(1) Dept. of engineering mechanics - school Superior of engineering of Bilbao

c/Alameda de Urquijo s/n E-48013 Bilbao. e-mail: imaceega@bi.ehu.es tf: + 34-946017235

(2) Fundación Tekniker - Dept. of processes of manufacture Avd. Otaola, 20 E-20600 Eibar, Guipúzcoa.

01/12/2002

1. Introduction

This work presents the numerical simulation of orthogonal cutting by means of finite element and experimental work done to validation [1-2].

The work aims to achieve a better understanding of the formation process of the chips that will be useful for the correct definition of the cutting parameters. The modelling of the process will make it possible to tackle a route of analysis more convenient than the one based on the method of trial and error, as usual in machining processes.

For the simulation of the process of cutting a finite element method has been used explicit rating.

The validation of the model has been through testing of orthogonal cutting, mecanizing hollow cylinders of steel operations of refrentado, under the same conditions in which is the modelizado.

2 Experimental

The parameters that are measured in trials are court - by means of a torque-indicating Allen platform forces - and the temperatures at 0.5 mm from the surface of the cutting edge of cutting - with a K thermocouple. Thermal infrared image maps are also obtained.
Figure 1. Result of the model developed with ABAQUS
Figure 1. Result of the model developed with ABAQUS

3. Results and discussion

Simulation of the Court provides values for shear forces close by 95% to the reals, and values of the temperatures in the area of retinal detachment with an error lower than 20%.

The factor of greatest influence at the Court is the angle of detachment of the blade, thus corroborating the simulation results from experiments.

4 Conclusions

The main conclusion of this work is that the numerical simulation by finite element is a valid tool for the analysis of orthogonal cutting in ductile materials, such as the common steels. The results obtained, in the form of forces of court or aspect of the chip, acceptably conform to the trials.

5 References

[1] M.R. Movahhedy, M.S. Gadala, y. Altimtas. Simulation of chip formation in orthogonal metal cutting process: an ALE finite element approach, Machining Science & Techn. 4 (2000), pp. 15-42.

[2] K. Komvopoulos and S.A. Erpenbeck, Finite Element Modeling of Orthogonal Metal Cutting, Journal of Engineering for Industry, 113 (1991), pp. 253-266

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