The aim of this thesis is to compare various simulation models of orthogonal
cutting process with each other as well as with various experiments. The effects
of several process parameters, such as friction and separation criterion, on the
results are analyzed. As simulation tool, commercial implicit finite element codes
MSC.Marc, Deform2D and the explicit code Thirdwave AdvantEdge are used.
Separation of chip from the workpiece is achieved either only with continuous
remeshing or by erasing elements according to the damage accumulated. From
the results cutting and thrust forces, shear angle, chip thickness and contact length
between the chip and the rake face of the tool can be estimated. For verification
of results several cutting experiments are performed at different cutting
conditions, such as rake angle and feed rate. Results show that commercial codes
are able to simulate orthogonal cutting operations within reasonable limits.
Friction is found to be the most critical parameter in the simulation, since good
agreement can be achieved for individual process variables by tuning it.
Therefore, simulation results must be assessed with all process variables and
friction parameter should be tuned according to the shear angle results. Plain damage model seems not appropriate for separation purposes of machining
simulations. On the other hand, although remeshing gives good results, it leads to
the misconception of crack generation at the tip of the tool. Therefore, a new
separation criterion is necessary to achieve both good physical modeling and
prediction of process variables.
| Identifer | oai:union.ndltd.org:METU/oai:etd.lib.metu.edu.tr:http://etd.lib.metu.edu.tr/upload/1049410/index.pdf |
| Date | 01 January 2003 |
| Creators | Bil, Halil |
| Contributors | Kilic, Engin |
| Publisher | METU |
| Source Sets | Middle East Technical Univ. |
| Language | English |
| Detected Language | English |
| Type | M.S. Thesis |
| Format | text/pdf |
| Rights | To liberate the content for public access |
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