Finite Element Modeling and Validation of Chip Segmentation in Machining of AISI 1045 Steel

• Published in: Procedia CIRP Vol. 58; pp. 499 - 504
• Main Authors: Devotta, Ashwin, Beno, Tomas, Siriki, Raveendra, Löf, Ronnie, Eynian, Mahdi
• Format: Journal Article
• Language: English
• Published: Elsevier B.V 2017
• Subjects: Chip morphologies; Chip segmentation; Cutting; Cutting conditions; Damage model; damage modeling; Finite element method; Forecasting; Machining centers; Manufacturing and materials engineering; Microstructure characterization; Output parameters; Production Technology; Produktions- och materialteknik; Produktionsteknik; Scanning electron microscopy; Shear stress; Stress triaxiality; Stress triaxiality factor; damage modeling; stress triaxiality; chip segmentation; Scanning electron microscopy; Cutting conditions; Stress triaxiality; Microstructure characterization; Forecasting; Chip segmentation; Damage model; Output parameters; Cutting; Stress triaxiality factor; Machining centers; Shear stress; Chip morphologies
• ISSN: 2212-8271; 2212-8271
• DOI: 10.1016/j.procir.2017.03.259

The finite element (FE) method based modeling of chip formation in machining provides the ability to predict output parameters like cutting forces and chip geometry. One of the important characteristics of chip morphology is chip segmentation. Majority of the literature within chip segmentation show cutting speed (vc) and feed rate (f) as the most influencing input parameters. The role of tool rake angle (α) on chip segmentation is limited and hence, the present study is aimed at understanding it. In addition, stress triaxiality's importance in damage model employed in FE method in capturing the influence of α on chip morphology transformation is also studied. Furthermore, microstructure characterization of chips was carried out using a scanning electron microscope (SEM) to understand the chip formation process for certain cutting conditions. The results show that the tool α influences chip segmentation phenomena and that the incorporation of a stress triaxiality factor in damage models is required to be able to predict the influence of the α. The variation of chip segmentation frequency with f is predicted qualitatively but the accuracy of prediction needs improvement.