Effect of constitutive material model on the finite element simulation of shear localization onset

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2020

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Elsevier

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Manufacturing Engineering
(2003)
Opened in 2003 with the aim to graduate experts in the field of machine-production, our Department is among the firsts in our country to offer education in English. The Manufacturing Engineering program focuses on the manufacturing technologies that shape materials from raw materials to final products by means of analytical, experimental and numerical modeling methods. First Manufacturing Engineering Program to be engineered by Müdek, our department aims to graduate creative and innovative Manufacturing Engineers that are knowledgeable in the current technology, and are able to use production resources in an effective and sustainable way that never disregards environmental facts. As the first Department to implement the Cooperative Education Program at Atılım University in coordination with institutions from the industry, the Manufacturing Engineering offers a practice-oriented approach in education with its laboratory infrastructure and research opportunities. The curriculum at our department is supported by current engineering software, and catered to creating engineers equipped to meet the needs of the production industry.
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Department of Mechanical Engineering
(2016)
The Mechanical Engineering Doctoral Program has started in 2016-2017 academic year. We have highly qualified teaching and research faculty members and strong research infrastructure in the department for graduate work. Research areas include computational and experimental research in fluid and solid mechanics, heat and mass transfer, advanced manufacturing, composites and other advanced materials. Our fundamental mission is to train engineers who are able to work with advanced technology, create innovative approaches and authentic designs, apply research methods effectively, conduct research and develop high quality methods and products in space, aviation, defense, medical and automotive industries, with a contemporary education and research infrastructure.

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Abstract

One of the most challenging problems in the field of machining is to determine the onset of shear localization. The consequences of the emergence of shear localized chips are fluctuations in the machining forces, tool wear, deterioration of the surface quality and out-of-tolerance machined components. Several constitutive material models are developed for the simulation of shear localization during machining, especially for Ti6Al4V. However, the accuracy and capability of the proposed models for the prediction of shear localization onset have not been investigated yet. In this study, the effect of different constitutive material models in the prediction of shear localization onset has been investigated. Different material models are studied including the Johnson-Cook (J-C) material model with Cockcroft-Latham damage model, J-C material model with a J-C damage model, models based on modified J-C material models (MJ-C) with strain softening terms, and material model with power-law type strain hardening and strain rate sensitivity, with polynomial thermal softening and polynomial temperature-dependent damage. The results of the finite element models are verified using orthogonal cutting experiments in terms of chip morphology and machining forces. Metallography techniques are used along with SEM observations to elucidate the distinction between continuous and shear localized chips. The results of this study indicate that three models are capable of predicting shear localization onset. However, when compared to the experiments, where a critical cutting speed of 2.8 m/min is obtained for shear localization onset, the results revealed that the model proposed by Sima and Ozel (2016) which is a model based on MJ-C model with temperature-dependent overarching modifier and temperature-dependent material model parameters is more accurate for the prediction of shear localization onset during machining Ti6Al4V. This model is shown to reveal a good prediction for the machining forces as well.

Description

Oliaei, Samad Nadimi Bavil/0000-0002-3202-1362; YILMAZ, Okan Deniz/0000-0002-5431-4334

Keywords

Finite element method, Shear localization, Constitutive material model, Ti6Al4V

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7

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104

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