Lecture 08 Fe Simulation of Cutting Processes PDF

Finite element simulation of cutting
processes
Simulation Techniques in Manufacturing Technology
Lecture 8
Laboratory for Machine Tools and Production Engineering

Chair of Manufacturing Technology
Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Dr. h.c. F. Klocke
© WZL/Fraunhofer IPT
Outline
1 Introduction
2 Requirements of the FE cutting simulation
3 CAD modelling for the FE cutting simulation
4 Constitutive material laws for the FE cutting simulation
5 Damage models for the FE cutting simulation and multiphase simulation
6 Friction and wear models for the FE cutting simulation
7 Criteria for the evaluation of FE software
8 Applications of the FE cutting simulation at the WZL
9 Summary and Outlook

© WZL/Fraunhofer IPT Seite 2
Influencing factors on the cutting process
Bild
eines
Prozesses
Workpiece material Cutting zone Tool Machine

structure chip forming cutting material machine design
mechanisms
texture coating
cooling lubricant
mechanical geometry
properties cutting parameters
drive system
hardness contact M
conditions
e.g.: friction, wear tool holder
residual stresses clamping device
heat transfer

Cutting process in comparison to other processes
Cutting process
Process Strain Strain rate / s-1 Thomolog
Extrusion 2–5 10-1 – 10-2 0.16 – 0.7
Forging /
0.1 – 0.5 10 – 10+3 0.16 – 0.7
Rolling
Sheet metal
0.1 – 0.5 10 – 10+2 0.16 – 0.7
forming
Cutting 1–5 10+3 – 10+6 0.16 – 0.9
Extreme conditions in the cutting process
Source: Jaspers

Outline
1 Introduction

Requirements to the FE cutting simulation
 Reproduction of the macro/ micro geometry of the tools and kinematic of the cutting
process
 Modelling of the thermo mechanical material behavior for the entire temperature and
strain rate range
 Implementation of damage approaches, texture microstructure and phase transformation
 Simulation of chip form (remeshing routine, material separation, etc.)

 Consideration of friction, wear and coating
 Modelling of heat generation and transfer (conduction, convection, radiation)
 Consideration of the influence of cooling lubricant
 Utilization of the Lagrangian solving method (instationary cutting processes)

 Generation of a finely structured FE mesh and adaptive remeshing (very high element
deformation because of higher gradients of deformation, temperature and tension)
 Appropriate computation time (explicit time integration, parallelization, etc.)

Cutting simulation: Input- und output parameters
Tool
Chip formation Strain
Temperature Tension
Tension Temperature
Deformation
Rate of deformation Cutting forces
Wear
Chip type
Chip flow
Chip crack Component
Strain
Temperatures
Deformation
Burr formation
Component / tool
Distortion
Geometry
Future:
Material data
Residual stresses
Contact conditions
Surface quality, e.g.: roughness,
Boundary conditions
changes in shape,
Cutting conditions
Measurement and position
Outline
1 Introduction

Macro- und micro tool geometry
major
Hauptschneide
cutting edge a
Querschneide
chisel edge
flank
Freifläface
che d
Construction dimensions DIN 6539 Major clearance angle: a = 10°

Type: N Twist angle: d = 35°
Diameter: d = 1 mm Cutting material: HW-K20
Drill-point angle: s = 118° Grain size: DK = 0.5 – 0.7 µm

Definition of element type

Creation of tool models close to reality
Drilling tool Determination of the tool geometry FEM-model
Real tool CAD-model
Macro
geometry
4 mm
Micro
geometry
6 µm 6 µm

Outline
1 Introduction
9 Summary
Zusammenfassung
and Outlook
Zusammenfassung und
und Ausblick
Ausblick
Thermo-mechanical behavior of material
   Bi  u i

Thermo-mechanical behavior of material
s  s ( ,  , T )
Strain Hardening Strain Rate Hardening Thermal Softening
450 450 450
-3 -1
d/dt=10 s & T=20°C =0.1 & T=20°C =0.1 & d/dt=1s
-1
400
400 300
s , MPa
350
300
350 150
250
AA6063-T6 AA6063-T6 AA6063-T6

200 300 0
0 0.1 0.2 0.3 0.4 -3 -1 1 3 0 100 200 300 400 500
10 10 10 10
, - -1 T , °C
Source: Diss- Abouridouane
Quelle: Diss-Abouridoaune d/dt , s
Constitutive material modelling for the FE cutting simulation
m
 Empirical models: e.g. Johnson-Cook-Modell
 T  Tr 
s  (A  B  )  (1  C ln( / 0 ))  (1  
n
 )
 Tm  Tr  Thermal softening
Strain hardening Strain rate sensitivity
 Micro mechanical models: e.g. enhanced Macherauch-Vöhringer-Kocks-model
1/ q 1/ p
  kT  0   
s  sa  s  1  
*
·ln      
  G 0    
0

 
Athermal processes Damping process
Thermal activated processes
 Semi-empirical models: e.g. Zerilli-Armstrong-model for bcc-materials
σ = ΔσG + C1 exp -C2T + C3T ln()  + C4 n + C5 L-1/2

Initial density
of dislocations Influence of temperature Influence of grain size
Dislocation jam
Source: Diss-Abouridouane
and strain rate
Determination of High speed flow curves
Split-Hopkinson-Pressure-Bar
Temperier-
Temperature
Projektil
Projectile chamber
kammer
Eingangsstab
Input rod Ausgangsstab
Output rod
Rohr
Tube
Bearing
Lager Probe
Sample Bearing
Lager Auffangbehälter
Collection bag
Preßluftbehälter
Air cylinder Split-Hopkinson-Tension-Bar Geweda
Prof. El-Magd
Joch
Joke Projectile
Projektil Eingangsstab
Input rod Ausgangsstab
Output rod
Tensile specimen
Zugprobe
Lager
Deckel mit Bearing Bearing
Rohr
Tube Cover with air Lager
Luftanschluss
connection
Strain rate: 500 s-1 – 10000 s-1
Temperature range: 93 K – 1273 K
Pressluftbehälter
Air cylinder with mit Projectile speed: 2,5 m/s – 50 m/s
Schnellöffnungsventil
quick release valve Projectile mass: m = 3,15 kg
Source: LFW

Material law for high strain rate deformation
K B     
n

 
kf
1  a  K ( B   )n    dt
ad
800
AA7075 T7351 K = 960 MPa
DPressure
ruckversutests
che B = 0.031
, MPa
n = 0.182
SpannungMPA
-6
700  / K = 6.25·10 s
d / dt =-1
ahreStress,
5010 s-1
600 4889 s-1
4350 s-1
4294 s-1
3450 s-1
True
500 3439 s-1
w
2558 s-1 Lines: Calculation
2529 s -1
0.001 s Symbols:
o experiments
: r
400
0 0.2 0.4 0.6 0.8
True plastic strain, -
Source: Diss-Brodmann

Outline
1 Introduction

Failure mechanisms
Loading type
Shear stress Tensile stress
TiAl6V4
20 µm 20 µm
Shear lokalisation model Pore growth model

(Imperfections theory) (Hancock-Mackenzie)

Damage modelling for the FE cutting simulation (ductile fracture)
 Macro mechanical failure models s
– Equivalent stress/ strain model: Dσ = σv,f / Dε = εv,f
s0
– Gosh-Model: DGosh = (1+σ2/σ1) σ12
– Ayada-Model: dD = (σm/σv) dεv E
 Micro mechanical failure models (Pore growth models)

 3 σm  εf 
– Hancock-Mackenzie-Modell ε f = ε n + α exp  - 
 2 σv 
2
 σV   3σ m 
   
2
– Gurson-Tveergard-Needleman-Model 0=  + 2fq cosh   - 1+ q f
σ  1  2σ   1

 V,M   V,M 
  σm    ε   T
– Johnson-Cook-Model ε f =  D1 + D2exp  -D3   1+ D4ln    1+ D5 
  σ 
v   ε 
 0   Tm 

Failure limit at tensile stress (r: Notch radius)
1.0 1.0
f = 0.05+2.89*exp(-2.35*sm/sv) f = 0.05+2.33*exp(-2.49*sm/sv)
stress εf f
0.8 0.8
Bruch-Vergleichsdehnung
0.6 glatt 0.6 glatt

r = 1.2 mm r = 1.2 mm
r = 0.8 mm r = 0.8 mm
0.4 0.4
failure-equivalent
r = 0.4 mm r = 0.4 mm
r = 0.02 mm r = 0.02 mm
0.2 0.2
TiAl6V4,  = 20°C TiAl6V4,  = 20°C
quasistatisch dynamisch
dynamic
0 quasi-static 0
0 0.5 1.0 1.5 2.0 2.5 0 0.5 1.0 1.5 2.0 2.5
1.5 1.5
f = 0.09+5.2*exp(-2.35*sm/sv) f = 0.09+3.54*exp(-2.61*sm/sv)
plastische
1.0 glatt 1.0

plastic
glatt
r = 1.2 mm r = 1.2 mm
r = 0.8 mm r = 0.8 mm
lokale
r = 0.4 mm r = 0.4 mm
0.5 r = 0.02 mm 0.5
r = 0.02 mm
Local
TiAl6V4,  = 200°C TiAl6V4,  = 200°C

quasistatisch dynamisch
dynamic
0 quasi-static 0
0 0.5 1.0 1.5 2.0 2.5 0 0.5 1.0 1.5 2.0 2.5
Multiaxiality sm/sv
Mehrachsigkeit

Criteria for chip formation
 Geometrical separation  Physical separation criterion  Without a specific

Geometrischen Trennkriterium
criterion Physikalisches Trennkriterium separation criterion
Geometrischen Trennkriterium Physikalisches Trennkriterium
As I As
As Trenn-I Distorted grid New networked
Trenn- As
Span Bs kriterium Separation
Chip Span Bs
Bs
kriterium
criterion topology grid topology
Bs
Cs vc Cs v
Cs vc IKR IKR D
c
Cs vc Tool Tool
Ds Tool
Werkzeug s Werkzeug
Ds Werkzeug Es Ds Werkzeug
Es Fs E Tool
X Es X X Fs s X
Hs,w GX
s,w F s,w E w Dw Cw B w H XGX F E Dw C B X
H s,w Gs,w Fs,w Ew Dw Cw Bw s,w s,w wHs,w Gw
s,w Fw
w
Ew wDw Cw Bw
dcr
dcr Sectional plane
Schnittebene Schnittebene
d Schnittebene Schnittebene
d
 Separation while exceeding
 Separation when an defined, maximum  Separation through
the cutting edge falls below a equivalent stress or at continuous remeshing for
critical distance dcr to the predefined maximum ductile material behavior
next workpiece node tensions

Chip separation - without chip separation criterion by remeshing
Old Mesh New Mesh

Elements are highly distorted Remeshing leads to better mesh
a) Span
Chip Werkzeug
Tool b)
New Mesh

Microstructure-based 3D modeling for micro cutting AISI 1045
Concept of the Representative Volume Element (RVE)
Capture of all significant microstructural Representativeness check of the RVE

inhomogeneities
1200
Tension stress Tension Compression
Microstructure
900
True stress MPa

Ø 0.1x0.1 mm
Compression stress
Macrostructure
600 FE model
RVE
Shear
Shear stress
Experiment
Two-phase 3D FE model 300
Cross section (0.1 x 0.1 x 0.1 mm) Longitudinal section
Quasi-static 0.1x0.1x0.1 mm
0
0 0.5 1.0 1.5 2.0
True plastic strain , , -
Pearlite Ferrite

Microstructure-based 3D FE model: Validation
Microstructure 50 Feed force 20
Drill
Two-phase FE model for N Nmm
40 22% Test Torque 16
micro drilling in Chip
ferritic-pearlitic carbon steel C45N 30 3% Test 7% 19% 12
Isotropic model
Isotropic model
Mixture model
Mixture model
20 8
Ferrite 10 4
Pearlite
0 0
Drill d = 1 mm, vc = 35 m/min, f = 12 µm
Workpiece
Holes
Workpiece Chip form

Influence on the formation of residual stresses
Thermally-induced phase
transformation
Thermal Metallurgical
state state
Heat gain
Residual stresses
Mechanical
State
 The complete coupling of the various parameters influencing the formation of residual
stresses has not been done
Source: Preckel

Input parameters for thermo-mechanical-metallurgic simulation
(residual stresses)
 Microstructure, initial state of texture
 Time dependent thermo-mechanical state of stress

 Mathematical approach for the diffusion controlled transformation kinetics:
Advanced Johnson-Mehl-Avrami-Kolmogrow-model, 1940
 Mathematical approach for the phase transformation without diffusion
Koistenen-Marburger-relation, 1959
 TTT/TTA-diagram for not isotherm conditions (high strain rate)
 Thermal material properties, depending on temperature (cp, l r …)
 Mechanical material properties, depending on temperature (E, u a ...)

 Elasto-viscoplastic material law
 Consideration of grain orientation, texture, micro damages, inclusions, etc.
 Description of the damage behavior on high strain rates

 Tool wear model
Outline
1 Introduction
8 Applications of the FE-cutting-simulation at the WZL

Friction model for FE cutting simulation
Thermal load at the workpiece and tool contact zone
Structure in the workpiece Distribution of temperature in the contact
zone
vc Shear edge Workpiece (according to Kronenberg)
Structure in the chip 300 chip

310
5 380 ºC
1 130 400
3 80 450
500 600 500
2
4 30 700
650
Tool flank
Cutting surface tool
600
Cutting edge Material: steel
Elastic limit: kf = 850 N/mm2
1 Primary shear zone Tool Cutting material: HW-P20
2 Secondary shear zone at rake face Cutting velocity: vc = 60 m/min
3 Jam and separation zone Chip thickness: h = 0,32 mm
4 Secondary shear zone at flank face
Rake angle: o = 10º
5 Run-up deformation zone
Deformation at the workpiece and tool contact zone
Structure in the workpiece Shear edge
vc
Structure in
the chip Shear zone
5
1 0,1 mm
3
2
4
Tool flank
Cutting surface
Cutting edge Turning tool

Tool Cutting edge
1 Primary shear zone
Material: C53E
2 Secondary shear zone at rake face
Cutting material: HW-P30
3 Jam and separation zone
Cutting velocity.: vc = 100 m/min
4 Secondary shear zone at flank face
Chip section: ap x f = 2 x 0,315 mm2
Mechanical stress at the workpiece and tool contact zone
Structure in the workpiece
vc Shear edge
𝜏, 𝜎
Structure
in the chip
5 Normal stress:
1 𝜎𝑛
3
4
2 Shear stress:
Tool flank
𝜏
Cutting surface Contact zone
𝑥
Cutting edge Tool
1 Primary shear zone Tool According to Oxley and Hatton

2 Secondary shear zone at rake face
3 Jam and separation zone
4 Secondary shear zone at the flank face
R  Coulomb friction model :
Coulomb friction
 R   s N
Shear friction
 Shear friction model:
reality kf
R  m k with k
3
 Continuous passover from dynamic friction
(Coulomb) to static friction (shear):
Dynamic friction Static friction
sN
Z.B.: Usui-model
R 𝜎𝑁
𝜏𝑅 = 𝑘 1 − exp⁡(−𝜇 )
𝑘
Orowan / Özel τR – shear stress from friction
sN – normal stress
reality Usiu
Shaw / k – yield stress in shear according to Mises
Wanheim and Bay kf – yield stress according to Mises
– friction coefficients
sN µ, m

Wear model for FE cutting simulation
Different types of wear at the cutting blade and wear mechanisms
Cutting- Edge chippage

Chip surface
Cutting
Tool edge
Crater wear
Crater wear
Flank
Built-up edge Flank abrasion

Flank wear
Workpiece
Oxidation notch
Sliding mechanisms Not-gliding mechanisms
Abrasion Adhesion Delamination Diffusion electrochemical Oxidation

Wear model for FE cutting simulation
Tool wear modelling
Differential
Tool life equations
wear models
Tool life acc. to Taylor: Tool life acc. to Hasting: Empirical tool wear Physical tool wear
A
T  v ck  Cv T  models models
B
T = tool life k, A, B = constant
u = temperature Cv = T für vc = 1 m/min
Adhesion Abrasion + Diffusion
Model acc. to Archard: Model acc. to Usui: Model acc. to Takeyama:
Adhesion / dV E
F S
C
dV ( 2 ) 
Abrasion  K  σ n  v ch  C1  e T dV
 G  v c  D  e R
dt 3H dt dt
dV/dt: wear-volume-rate K, C1, C2, G, D: constant
H: hardness sn: normal stress
F: mechanical load Vch: chip sliding speed
S: cutting length u: temperature
Object boundary conditions
Boundary Conditions
Object Conditions Inter Object Conditions Environment Object Conditions
Tool
Workpiece
2D FEM Cutting Model

Boundary Conditions
Friction Heat Transfer
Tool
Movement
=
Object 1
Workpiece = Object 2

Boundary conditions
Boundary Conditions
Self Contact (Chip vs. Workpiece Surface)

Object Conditions

FN
Movement
FR
FR: Friction Force

FN: Normal Force
Workpiece = Object 2

Boundary Conditions The workpiece is moving in
x-direction with the prescribed
velocity vc. It is fixed in y-direction
Object Conditions
Tool is fixed in x- and y-direction!

Tool
Movement
Cutting
speed vc in y
x-direction
Workpiece x

Boundary Conditions
Tool
Object Conditions
Heat Transfer
Movement
Workpiece

Boundary Conditions
Tool
FN
FN
FR Heat Transfer
FN
Boundary Conditions
Heat Transfer
Tool
Heat Convection Heat Emissivity
Heat Radiation
Heat Convection
Heat exchange with

environment

Outline
1 Introduction
8 Applications of the FE-cutting-simulation at the WZL

FEM software solution for FEM simulation of the cutting process
MSC.Marc
Criteria for the evaluation of FE software
Programm ABAQUS ANSYS/ LS-DYNA AdvantEdge DEFORM COMSOL

Criteria
Creation of geometries Creation of geometries Import of CAD data Creation of simple Creation of simple Creation of simple
and import of CAD data geometries and geometries and geometries and import
import of CAD data import of CAD data of CAD data
Material catalogue No, has to be defined Yes, expandable Yes, wide Yes, new catalogue yes
importable
Element type Every type Every type tetrahedron, tetrahedron, rectangle Every type
rectangle
Time integration Implicit / Explicit Implicit / Explicit Explicit Implicit Implicit
Remeshing routine none none yes yes yes
use general general cuttingprocess Deforming process general
Influence on simulation High, by Python Possible, by Fortran no High, by Fortran High, by Matlab
computation
parallelisation possible possible possible possible possible
Usage at the WZL Eigenfrequency analysis, no no Cutting simulation Thermo-elastic
elast. Tool behavior, deformation
elasto-plastic component
behavior
Source: SIMULIA, ANSYS, LSTC, TWS, SFTC, COMSOL

Outline
1 Introduction

Applications of the FE cutting simulation at WZL
2D, e.g. Planing
Drilling Milling
Turning
Research focus at the WZL:

 Process optimization
 Material modelling

Simulation of the high speed cutting process
Cutting speed: vc = 3000 m/min

Feed: f = 0.25 mm
vc







Comparison of different thermal properties of the tools
Orthogonal turning 2D (vc = 300 m/min, f = 0,1 mm, C45E)
Ceramic-Insert WC-Insert
Thermal conductivity l = 35 W/mK Thermal conductivity l = 105 W/mK
Tmax = 650°C Tmax = 550°C

Temperature distribution in dependency of the coating and
its thickness
3 µm TiN 6 µm 570
557
Calculated temperature at the

560
chip bottom side TSp / °C

550
Tsp 539 539
540
533
530
520
509
510
TiN 6 µm Al2O3 0
Coating TiN TiN HW TiN Al2O3
Thickness 3 µm 6 µm 6 µm 6 µm
Heat conductivity: Heat capacity:

HW: 100 W/(mK) HW: 3,5 J/(cm³K)
TiN: 26,7 W/(mK) TiN: 3,2 J/(cm³K)
Al2O3: 7,5 W/(mK) Al2O3: 3,5 J/(cm³K)
Material: C45E+N Cutting Material: HW-K10/20

Tensile strength: Rm = 610 N/mm²
FE-Based calibration process for tool wear model
Modeling
Verschleißmarkenbreite über die Schnittzeit
Machining experiments Wear curve

16MnCr5 (einsatzgehärtet), Stegbreite = 1 mm, cBN bestückte Einstechplatte der Sorte N151.2-600-50E-G
Schnittgeschwindigkeit vc = 150, 200, 300 m/min und Vorschub f = 0,06 mm
120
vc = 250 m/min vc = 200 m/min vc = 150 m/min
Tool-wear VB
100
Verschleißmarkenbreite VB [µm]
80
60
t = 10 min
40
t = 6 min
t = 4 min
20
t = 1 min
0
0 5 10 15 20 25 30 35 40
Cutting time t Schnittzeit t [min]
dW/dt
Determination of the Regression analysis FE-analysis
specific material lg C1
parameters C1 and C2  Temperature
lg {w /( sn VS)}
 Normal-
C2 tension
C
dW ( 2 )
 σ n  v ch  C1  e T  Sliding speed
dt
1/T

2D FE model for tool wear simulation
Verschleiß VB [mm]
Tool life

Phase 3: Methodology for moving the nodes at the rake face
Tool
node square element
Tool
Workpiece vc
Rake
Chip
vc

Phase 3: Methodology for moving the nodes at the flank face
node square element
5 µm Tool
nA nB nC nD Flank
A B C D
nA = nB = nC = nD
Workpiece

Verification of the tool wear simulation for the flank wear
vc = 150 m/min, f = 0.06 mm, ap = 1 mm, dry
eff = -26°
Tool
Time: a0 = 7° Time: Time: Time: 93 µm

5 min 15 min 25 min 35 min
[mm]
0,1
VB [mm]
Experiment
0,08
Width VB/
0,06
Wearwidth
Simulation
0,04
wear
0,02
Flank
Flank
0
0 5 10 15 20 25 30 35
Cutting time t [min]
Time [min]
Setup of a 3D FE model
15°
15°
7,5°
Setup of a 3D FE model - specification of the tool holder
Tool holder:
RotZ=6° Z
Kennametal
ID: PCLNL252M12 F4 NG27
Rake angle 0 = -6°
Relief angle a0 = 6°
Tool inclination angle ls = -6°
Rotx=-6° X
Y
Tool cutting edge angle r = 95°

Setup of a 3D FE model - Tool position
r tool
ap
r workpiece
r tool =r workpiece

Setup of a 3D FE model - Mesh of the workpiece

3D simulation
Temperature Workpiece: AISI 1045

Tool: K10
vc = 300 m/min
f = 0,1 mm
Cutting Force Fc

3D FE model - Post processing
Temperature (°C)
For better visualization
the tool is hidden

Temperature (°C)
the tool is hidden

Strain distribution
Strain
the tool is cut

Strain Rate
Strain Rate
distribution
the tool is cut

Models of cutting inserts
Roughing geometry Finishing geometry
CNMG120408RN CNMG120408FN

Simulation of the chip flow
Chip breaker RN Chip breaker FN
Material:
C45E+N
Cutting material:
HC P25
Insert:
CNMG120408
Insert geometry:
a0 0 lS r 
6° -6 ° -6° 95° 90°
Cutting velocity.:
vc = 300 m/min
Feed:
f = 0,1 mm
Depth of cut:
ap = 1 mm
Dry cutting

Simulation of the chip flow
Chip breaker RN Chip breaker FN
Material:
C45E+N
Cutting material:
HC P25
Insert:
CNMG120408
Insert geometry:
a0 0 lS r 
6° -6 ° -6° 95° 90°
Cutting velocity.:
vc = 300 m/min
Feed:
f = 0,1 mm
Depth of cut:
ap = 1 mm
Dry cutting

Comparison of simulation and real chip flow
CNMG120408
Chip breaker NF
HC-P15
r = 95°
n = -6°
ls = -6°
C45E+N
ap = 1,9 mm
f = 0,25 mm
vc = 200 m/min
dry
vf
vc

Drilling: Modelling of size effects
Task:
Development of a consistent 3D computation model based on the FE method
for scaling the drilling process in consideration of size effects
n
drill
f Bohrwerkzeug
Friction
Reibung Reibung
Friction
Workpiece
Werkstück
Plastic
Plastische Separation
Stofftrennungof material
deformation
Verformung

Previous results: 3D FE computation model for d = 1 – 10 mm
Material modeling Measuring the drill geometry FE boundary conditions
s  s(, , T) Tool FEM-Model
Strain hardening Cutting parameters
Plasticity Tool: rigid / elastic
Damping mechanism Friction law
Relaxation Heat transfer
Dynamic strain ageing Element size
Temperature influence Number of elements
Loss of cohesion Remeshing strategy
Failure mechanism Degree of freedom

FE-Simulation of the drilling process with d = 1 mm (DEFORM 3D)
Machining conditions
Workpiece material: C45E+N
Tool material: HW-K20
Cutting speed: 35 m/min
Feed: 0.012 mm/U
Feed velocity: 133 mm/min
Cooling lubricant: none
Boundary Conditions
Tool:
rigid
number of elements: 90 000
Workpiece:
visco-plastic (LFW-material law),
temperatur fixed at boundary nodes
number of elements: 100 000
Contact:
coulomb friction ( =0,2)
heat transfer (conduction & convection)
Computing time and drilling depth:
2000 h; 0.18 mm (70% of the major cutting edge)
Verification of the chip formation
Experimental chip formation Chip formation in the simulation
Workpiece material: C45E+N Cutting speed: vc = 35 m/min

Cutting tool material: HW K20 Feed: f = 0.012 mm

Model validation: Scaling effect of the chisel edge length
6
32
Workpiece:
Verhältnis (dQ / d) [%]

]
30
C45E+N
2
kf,max [kN/mm
5 28
2]
26
force kf,max [kN/mm
Cutting speed:
24
vc = 35 m/min
4 22
20
feedVorschubkraft
1 2 3 4 5 6 7 8 9 10
Feed:
Durchmesser d [mm]
3 Diameter d [mm] f = 0,012 * d
Cutting tool material:

2 HW-K20
spezifische
Experiment
Specific
1 Corner radius:
Simulation
kf,max = 2 * Fz,max / (d * f) rn = 4 µm
0 Cooling:
1 2 3 4 5 6 7 8 9 10
None
DrillBohrerdurchmesser
diameter d [mm] d [mm]

Model validation: Temperature at the main cutting edge (center)
400
Experiment
major cutting edge T [°C]
Simulation d = 3 mm
300
Temperature at the
200
100
0
1 3 8 10
Diameter d [mm]
Cutting speed: vc = 35 m/min Workpiece: C45E+N

Feed: f = 0,012 * d Cutting tool material:HW-K20
Coolant: None Rounding: rn = 4 µm
Modelling of the face milling process
Materials and cutting parameters:
 Work material: Quenched and tempered AISI 1045 (normalized)
 Tool material: Coated WC
 Cutting parameters:
v
– No. of teeth: z=4 f
– Diameter: D = 32 mm n
– Engagement angle: φA – φE = 180°
Tool
– Feed: f = 0.5 mm
r
– Feed per tooth: fZ = 0.125 mm ap
– Depth of cut: ap = 0.8 mm Workpiece
– Tool leading angle: κr = 90°

f
z
– Tool inclination angle: λ = -5°
– No. of rev.: n = 2250 min-1

Axial and radial rake angle:

 Axial rake angle γaxial = 9°
 Radial rake angle γradial = 5°
γaxial

 Depth of cut ap
r = r Workpiece
 Feed f tool
 Workpiece geometry f
r Tool
View
ap
r Workpiece

Finding the best workpiece geometry
1. Simplified
workpiece
geometry
2. Simplified work-
piece geometry
1 2
3. Simplified work-
piece geometry

Simulation results for the 1. simplified workpiece model
 Rough elements within the
work piece
 Simulation of chip formation
not accurate enough
back

Simulation results for the 3. simplified workpiece model
Final workpiece geometry
Left Right

Results for the face milling operation
Chip formation for the left
side of the work piece:
 at the beginning very thin
chips are produced
 chip curling starts for higher
undeformed chip thickness

Verification of the FE model
Simulation Experiment
.
Full agreement

FE based sensitivity analysis
Varied input  Heat capacity Goal output  Cutting force Fc

parameters: parameters:
 Thermal conductivity  Passive force Fp
 Flow stress  Feed force Ff
 Friction coefficient  Temperature T
 Tool micro-geometry
Legend
Heat Thermal Flow Tool Friction
capacity conductivity stress micro-geometry
Influence
Cutting force
low
Feed force
medium
Passive force
high Temperature

Outline
1 Introduction

Outlook:
Benchmark-Analysis to choose the best tool geometry
Fixed input Cutting Benchmark-Analysis
parameter simulation
material parameter, Cutting parameter 1
friction coefficients Cutting parameter 2
+ #
Flank wear VB
Cutting parameter Q,
1 2 T,
vc1, ap1, f1 vc2, ap1, f1 Fi,
+ Determination of the
Tool thermomechanical
A B C A B C
loadspectrum, chip
Tool
flow, chip form
Temp Wear Stress Chip

flow Optimised
+ Tool A + - ++ - tool-
Coating and
Tool B - -- o + tool carrier-
TiN TiAlN AlO2
Tool C ++ ++ + + geometry

Summary
 Machining process: System of complex physically coherent operations
 A holistic and comprehensive simulation of the machining has not been achieved with
conventional empirical or analytical approaches
 FEM is a promising method for the holistic simulation of machining

– High flexibility
– Implementation of various models that describe the aspects of machining
– Complete reproduction of the machining process
 The FE cutting Simulation gives good results under the following boundary conditions:
– Realistic reproduction of the tools macro/ micro geometry
– Adequate modeling of the thermo mechanical material behavior
– Exact capturing of the boundary conditions (friction, heat transfer, wear , cooling lubricant, damage,
micro structure, etc.)
Questions
 What are the ranges of temperature, strain and strain rate in cutting operations?
 What is the range of strain rate, that can be realized by the Split-Hopkinson-Bar-Test?
 Name two friction models. What are the advantages and the disadvantgeas of these
models?
 How is the strain rate effecting the flow stress curve of a material?
 What are the demands on a temperature measurement setup which allows the evaluation
of simulation results?
 Explain the difference between the orthogonal cutting process and the longitudinal cutting
process!
 Explain the difference between a plastic and an elastic-plastic flow stress curve!

Lecture 08 Fe Simulation of Cutting Processes PDF

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Finite element simulation of cutting

Laboratory for Machine Tools and Production Engineering

Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Dr. h.c. F. Klocke

2 Requirements of the FE cutting simulation

3 CAD modelling for the FE cutting simulation

4 Constitutive material laws for the FE cutting simulation

5 Damage models for the FE cutting simulation and multiphase simulation

6 Friction and wear models for the FE cutting simulation

7 Criteria for the evaluation of FE software

8 Applications of the FE cutting simulation at the WZL

9 Summary and Outlook

Workpiece material Cutting zone Tool Machine

© WZL/Fraunhofer IPT Seite 3

Extrusion 2–5 10-1 – 10-2 0.16 – 0.7

Cutting 1–5 10+3 – 10+6 0.16 – 0.9

Extreme conditions in the cutting process

© WZL/Fraunhofer IPT Seite 4

2 Requirements of the FE cutting simulation

3 CAD modelling for the FE cutting simulation

4 Constitutive material laws for the FE cutting simulation

5 Damage models for the FE cutting simulation and multiphase simulation

6 Friction and wear models for the FE cutting simulation

7 Criteria for the evaluation of FE software

8 Applications of the FE cutting simulation at the WZL

9 Summary and Outlook

 Simulation of chip form (remeshing routine, material separation, etc.)

 Consideration of the influence of cooling lubricant

 Utilization of the Lagrangian solving method (instationary cutting processes)

© WZL/Fraunhofer IPT Seite 6

2 Requirements of the FE cutting simulation

3 CAD modelling for the FE cutting simulation

4 Constitutive material laws for the FE cutting simulation

5 Damage models for the FE cutting simulation and multiphase simulation

6 Friction and wear models for the FE cutting simulation

7 Criteria for the evaluation of FE software

8 Applications of the FE cutting simulation at the WZL

9 Summary and Outlook

Construction dimensions DIN 6539 Major clearance angle: a = 10°

© WZL/Fraunhofer IPT Seite 9

© WZL/Fraunhofer IPT Seite 10

© WZL/Fraunhofer IPT Seite 11

2 Requirements of the FE cutting simulation

3 CAD modelling for the FE cutting simulation

4 Constitutive material laws for the FE cutting simulation

5 Damage models for the FE cutting simulation and multiphase simulation

6 Friction and wear models for the FE cutting simulation

7 Criteria for the evaluation of FE software

8 Applications of the FE cutting simulation at the WZL

© WZL/Fraunhofer IPT Seite 13

AA6063-T6 AA6063-T6 AA6063-T6

σ = ΔσG + C1 exp -C2T + C3T ln()  + C4 n + C5 L-1/2

© WZL/Fraunhofer IPT Seite 16

© WZL/Fraunhofer IPT Seite 17

2 Requirements of the FE cutting simulation

3 CAD modelling for the FE cutting simulation

4 Constitutive material laws for the FE cutting simulation

5 Damage models for the FE cutting simulation and multiphase simulation

6 Friction and wear models for the FE cutting simulation

7 Criteria for the evaluation of FE software

8 Applications of the FE cutting simulation at the WZL

9 Summary and Outlook

Shear lokalisation model Pore growth model

© WZL/Fraunhofer IPT Seite 19