Rodríguez Juan Manuel, Larsson Simon, Carbonell Josep Maria, Jonsén Pär
Department of Mechanical Engineering, EAFIT University, Medellin 050022, Colombia.
Division of Mechanics of Solid Materials, Luleå University of Technology, 97187 Luleå, Sweden.
Materials (Basel). 2020 Apr 24;13(8):1979. doi: 10.3390/ma13081979.
Machining of metals is an essential operation in the manufacturing industry. Chip formation in metal cutting is associated with large plastic strains, large deformations, high strain rates and high temperatures, mainly located in the primary and in the secondary shear zones. During the last decades, there has been significant progress in numerical methods and constitutive modeling for machining operations. In this work, the Particle Finite Element Method (PFEM) together with a dislocation density (DD) constitutive model are introduced to simulate the machining of Ti-6Al-4V. The work includes a study of two constitutive models for the titanium material, the physically based plasticity DD model and the phenomenology based Johnson-Cook model. Both constitutive models were implemented into an in-house PFEM software and setup to simulate deformation behaviour of titanium Ti6Al4V during an orthogonal cutting process. Validation show that numerical and experimental results are in agreement for different cutting speeds and feeds. The dislocation density model, although it needs more thorough calibration, shows an excellent match with the results. This paper shows that the combination of PFEM together with a dislocation density constitutive model is an excellent candidate for future numerical simulations of mechanical cutting.
金属加工是制造业中的一项基本操作。金属切削过程中的切屑形成与大塑性应变、大变形、高应变率和高温有关，主要发生在第一和第二剪切区。在过去几十年中，加工操作的数值方法和本构模型取得了显著进展。在这项工作中，引入了粒子有限元法（PFEM）和位错密度（DD）本构模型来模拟Ti-6Al-4V的加工过程。这项工作包括对钛材料的两种本构模型的研究，即基于物理的塑性DD模型和基于唯象学的Johnson-Cook模型。这两种本构模型都被应用到一个内部开发的PFEM软件中，并进行设置以模拟钛Ti6Al4V在正交切削过程中的变形行为。验证表明，对于不同的切削速度和进给量，数值结果与实验结果一致。位错密度模型虽然需要更全面的校准，但与结果显示出极好的匹配度。本文表明，PFEM与位错密度本构模型的结合是未来机械切削数值模拟的一个极佳选择。
