Ammar Mohamed M A, Shirinzadeh Bijan, Elgamal Hassan, Nasr Mohamed N A
Department of Mechanical Engineering, Faculty of Engineering, Alexandria University, Alexandria 5424041, Egypt.
Robotics and Mechatronics Research Laboratory, Department of Mechanical and Aerospace Engineering, Monash University, Clayton 3800, Australia.
Sensors (Basel). 2022 Nov 6;22(21):8547. doi: 10.3390/s22218547.
This study focuses on the role of the damage evolution when estimating the failure behavior of AISI 1045 steel for sensing and measuring metal cutting parameters. A total of five Lagrangian explicit models are established to investigate the effect of applying damage evolution techniques. The Johnson-Cook failure model is introduced once to fully represent damage behavior, i.e., no damage evolution is considered, and as a damage initiation criterion in the remaining approaches. A fracture energy-based model is included to model damage propagation with different evolution rates. Temperature-dependent and temperature-independent fracture energy models are also investigated. Dry orthogonal cutting and residual stresses measurements of AISI 1045 are conducted for validation. The significance of the damage evolution is investigated using honed-tool and sharp-tool models. Including the damage evolution led to a prediction of higher workpiece temperatures, plastic strains, cutting forces, and residual stresses, with no clear differences between linear and exponential evolution rates. The role of damage evolution is more evident when temperature-dependent evolution models are used.
