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Modeling of Chip Breakage in Machining of AISI 1045 Steel by Using an Improved Damage Mechanics Model
Author(s) -
Wu Bo,
Buchkremer Stefan,
Münstermann Sebastian,
Lian Junhe,
Veselovac Drazen,
Bleck Wolfgang,
Klocke Fritz
Publication year - 2017
Publication title -
steel research international
Language(s) - English
Resource type - Journals
SCImago Journal Rank - 0.603
H-Index - 49
eISSN - 1869-344X
pISSN - 1611-3683
DOI - 10.1002/srin.201600338
Subject(s) - breakage , machining , chip formation , finite element method , chip , materials science , structural engineering , stress (linguistics) , mechanical engineering , engineering , mechanics , composite material , tool wear , physics , linguistics , philosophy , electrical engineering
Modeling of chip breakage is challenging due to the complex loading conditions in the machining process. This paper is dedicated to the finite element modeling of chip breakage with damage mechanics approaches. In this study, the extended modified Bai–Wierzbicki model, which has been successfully implemented in modeling of chip formation and flow in a previous study, is supplemented with an effective damage concept to simulate chip breakage. The model takes the influence of temperature, strain rate, stress state, and the loading history of a chip breakage cycle into consideration. The emphasis is placed on the loading paths under fiercely varying stress states during external longitudinal turning processes, which has significant influence on the damage behavior of materials. An effective damage concept based on cut‐off value is proposed, which differentiates the effect of accumulated plastic strains on damage in different phases of the chip breakage cycle in turning processes. The material model successfully predicts the chip breakage behavior in turning processes conducted with different process parameters and tools.