Dual-zone contact model for process

modelling of machining operations

 OBJECTIVE
Process
Models

Semi – Analytical
FEM
Analytical Models

Thin Shear
Mechanistic Slip Line
Zone

Dual Zone
Model
 Orthogonal Cutting

MS 402 Integrated Manufacturing Systems – 2010 SPRING

 PRIMARY SHEAR ZONE

  γ  
n
 &     T − Tr 
v
τ =
1 
A + B    1 + m ln  γ   1 −   
Johnson Cook 3 3   
 γ&   T −T  
    0     m r  
 PRIMARY SHEAR ZONE
• Conservation of momentum
Shear Stress τ 1 = ρ (V sin φ )2 γ 1 + τ 0
β  2 2 γ 2 
• Conservation of energy T = Tw + 
ρc 
ρ V sin φ
2
+ τ γ
0 



• Compatibility condition

MS 402 Integrated Manufacturing Systems – 2010 SPRING

 DUAL ZONE CONTACT

α
A
TOOL
Fs
h1 φ
Ft B γ
Fn

Ff Sticking contact length

R F

and
α
N Total contact length

Apparent friction coefficient

vs
Sliding friction coefficient
Stress Distributions

ζ ζ
 x  l 
τ ( x ) = µP0 1 −  τ 1 = µP0 1 − p 
 lc   lc 
  τ  1ζ 

l p = l c  −  1
 + 1
  P0 µ  
 
MS 402 Integrated Manufacturing Systems – 2010 SPRING
 Normal Force at the Rake Face

CHIP C Np Ne

α TOOL
A Fp Fe
F B C
h1 φ
s ℓp ℓe
F B γ ℓc
Fn t
wh1
Ff Fs = τ 1
R F
sin φ
α
N

ζ
lc
 x
lc
wl c cos λ a
N = ∫ P ( x )dx = ∫ P0 1 −  wdx = P0 N = Fs
0 0  lc  ζ +1 (
cos φ + λ a − α )
h1 (ζ + 1) cos λ a
P0 = τ 1
(
l c sin φ cos φ + λ a − α )
MS 402 Integrated Manufacturing Systems – 2010 SPRING
 Moment Equilibrium
at the Tool Tip
AB tan (φ + λ a − α )
M AB = Fn = Fs h1
2 2 sin φ
M AB = M BC
ζ
  cos λ a
lc
x l
M BC = ∫ xP0 1 −  wdx = Fs c
0  lc  ζ + 2 cos(φ + λ a − α )

ζ + 2 sin (φ + λa − α )
l c = h1
2 sin φ cos λa

MS 402 Integrated Manufacturing Systems – 2010 SPRING

 Apparent Friction Coefficient
µa = F / N
ζ
 x−lp
lp lc
  l 
F = ∫ τ 1 wdx + ∫ τ 1 1 −  wdx = τ 1 w l p + e 
0 lp  le   ζ +1
lc lc ζ
 x wl c
N = ∫ P ( x )dx = ∫ P0 1 −  wdx = P0
 
0 0  lc  ζ +1
τ 1 l p (ζ + 1) + l e   τ  1ζ


µa = l p = l c  −  1
 + 1
  P0 µ  
P0 lc  

τ 1    τ 1 / ς 
 τ1 ς + 2 sin(2(φ + λa − α ))
µ a = tan(λ a ) = 1 + ς 1 −  1  =
  P0 µ   4(ς + 1)
P0
   P0 (cos λa ) 2

MS 402 Integrated Manufacturing Systems – 2010 SPRING

 Calculation of Shear angle
3200

1. Minimization of Energy 3100

3000

cutting power - W
2900

2800

2700

2600

2500
20 25 30 35 40
shear angle - degrees

α β
2. Merchant : φ = 45 +
2
−
2
3. Zvoyrkin :

MS 402 Integrated Manufacturing Systems – 2010 SPRING

Calculation of Cutting Forces
wh1 cos(λ a − α )
Fc = τ 1
sin φ cos(φ + λa − α )
wh1 sin (λ a − α )
CHIP
C

Ff = τ1
α
TOOL sin φ cos(φ + λ a − α )
A
F
h1
φ
s

F B γ
t
Fn

Ff
R F

α
N

MS 402 Integrated Manufacturing Systems – 2010 SPRING

 Inputs
• Cutting Parameters
– Depth of cut, feed rate, cutting speed,
– Tool geometry: rake angle
• Material Model
– Constitutive equation
• Friction Coefficient
– Sliding vs Average (apparent) – related to
chip velocity

MS 402 Integrated Manufacturing Systems – 2010 SPRING

 WORKING OF THE MODEL
Calibrated

Shear Stress Material Model

Coefficients
Orthogonal Tube Shear Angle Dual Zone
Cutting Tests Model
Apparent friction Sliding Friction
coefficient Coefficient

Cutting Forces
Material Model
Shear Stress
Dual Zone and Angle
Sliding Friction
Coefficient Model Pressure
Distribution Temperature
Cutting Distribution
Parameters Contact Lengths
 Solution Procedure for
Prediction
• For a given shear angle range:
– Calculate Chip velocity,
– Select an apparent friction coeff.
• Calculate friction angle
• Calculate sliding friction coeff. (by using the
calibrated value)
• Calculate To1/P0
• Calculate apparent friction coeff.
• Check the selected and calculated apparent
friction values

MS 402 Integrated Manufacturing Systems – 2010 SPRING

 Solution Procedure cont.
– Calculate total contact length
– Calculate To0 by iteration
– Calculate To1
– Calculate P0
– Calculate sticking contact length
– Calculate the cutting forces
– Calculate the cutting power
• Select the shear angle which corresponds
to the minimum cutting power.
MS 402 Integrated Manufacturing Systems – 2010 SPRING
Calibrated JC Parameters
Material A (MPa) B (MPa) n m v

AISI 1050 880 500 0.234 0.0134 1

AISI 4340 945 500 0.26 0.015 1

Ti6Al4V 649 490 0.28 0.028 1

  
n
  &    T − Tr
v

1  γ  1 + m ln γ

τ= A + B  1 −   
 γ&   T −T  
3  3     0    m r  
 
 Sliding Friction Coefficient
AISI 1050 Steel
0.7 0.7

sliding friction coefficient

sliding friction coefficient

0.6
Uncoated 0.6

0.5
Carbide 0.5

0.4 0.4

0.3 0.3

0.2 non-cutting tests 0.2

cutting tests
Coated non-cutting tests
0.1 0.1 cutting tests
0
Carbide
0
0 200 400 600 800 0 200 400 600 800
friction speed (m/min) friction speed (m/min)

0.7 0.7

sliding friction coefficient

sliding friction coefficient

0.6 0.6

0.5
Ceramic 0.5

0.4 0.4

0.3 0.3

0.2 0.2

0.1
CBN 0.1

0 0
0 200 400 600 800 0 200 400 600 800
friction speed (m/min) friction speed (m/min)
Non-cutting Friction
Measurement

µ = F friction / Fnormal

MS 402 Integrated Manufacturing Systems – 2010 SPRING

 Sliding Friction Coefficient
0.7

sliding friction coefficient

0.6

Uncoated 0.5
vs AISI 4340
Carbide 0.4

0.3

0.2

0.1 non-cutting tests

cutting tests
0
0.7 0 200 400 600 800
friction speed (m/min)
sliding friction coefficient

0.6

0.5

0.4

0.3

0.2 HSS vs Ti6Al4V

0.1

0.0
0 2 4 6 8 10
friction speed (m/min)
 Calibrated Friction Coefficient

Material – Tool µs ( V in m/min)

AISI 1050 – Uncoated Carbide
AISI 1050 – Coated Carbide
AISI 1050 – CBN
AISI 1050 – Ceramic
AISI 4340 – Uncoated Carbide
0.398 + 6.120 × 10 −4 V
0.8932 + 1×10−6V 2 − 0.0016V
0.431 − 7 × 10 −5 V
0.4311 + 2 × 10 −4 V
0.513 + 4.734 × 10 −6 V 2 − 1.872 × 10 −3 V

Ti6Al4V – HSS 0.326 + 1.1 × 10 −3 V

Contact Measurement on
Microscope
Effect of Cutting Speed on the
Contact AISI 1050 – Coated
100 m/min Carbide
chip flow direction

hone
sliding

sticking

300 m/min

600 m/min
 Rake Angle and Friction
0.52 0.12

sticking length (mm)

0.51
apparent friction
0.1
0.5
coefficient

0.08
0.49
0.06
0.48
0.04
0.47
0.02
AISI 1050 0.46
0.45 0
-15 -10 -5 0 5 10 15
Coated -15 -10 -5 0 5 10 15

rake angle (degrees) rake angle (degrees)

carbide
0.5 0.25
300 m/min

sticking/total contact
total contact length

0.45 0.2

length (mm)
0.1 mm/rev 0.4 0.15
(mm)

0.35 0.1

0.3 0.05

0.25 0
-15 -10 -5 0 5 10 15 -15 -10 -5 0 5 10 15

rake angle (degrees) rake angle (degrees)

 Important Observations
• Feed ℓc
• Cutting speed ℓc
• Cutting speed ℓp (down to 0)
• In general %15 of the total contact is sticking
• ℓc≈3-5 times feed, ℓp≈<1.5 times feed
• Apparent friction coefficient strongly depends
on ℓp/ℓc
– Which explains the rake angle effect on the
friction
 Verification of Cutting Forces
Orthogonal Cutting
AISI 1050 – Uncoated Carbide Tool rake=5º
800 800

600 600

Forces - N
Forces - N

400 400

200 200

0 0
0.03 0.05 0.07 0.09 0.11 0.13 0.15 0.17 0.03 0.05 0.07 0.09 0.11 0.13 0.15 0.17
V=152 m/min feed rate - mm/rev V=216 m/min feed rate - mm/rev

800

600
Forces - N

400

200

0
0.03 0.05 0.07 0.09 0.11 0.13 0.15 0.17
V=304 m/min feed rate - mm/rev
 Verification of Cutting Forces
Orthogonal Cutting
AISI 1050 – Uncoated Carbide Tool rake=-5º
900 900

700 700

Forces - N
Forces - N

500 500

300 300

100 100
0.07 0.09 0.11 0.13 0.15 0.17 0.07 0.09 0.11 0.13 0.15 0.17
V=150 m/min feed rate - mm/rev V=213 m/min feed rate - mm/rev

900

700
Forces - N

500

300

100
0.07 0.09 0.11 0.13 0.15 0.17
V=300 m/min feed rate - mm/rev
 Verification of Cutting Forces
Orthogonal Cutting
Ti6Al4V – HSS Tool
70 70
60 dual zone - feed force 60 mechanistic - feed force
number of test in %

number of test in %
50 50
dual zone - tangential force mechanistic - tangential force
40 40
30 30
20 20
10 10
0 0
0--10

11--20

21--30

31--40

41--50

51--60

61--70

71--80

81--90

91-100

0--10

11--20

21--30

21--40

41--50

51--60

61--70

71--80

81--90

91-100
% error in predictions % error in predictions

Total of 36 tests
Comparison with the
mechanistic model
 Effect of Friction Model on Cutting
Force Predictions
Shear Stress Distribution
Model
on the Rake
τ = τ1 x ≤ lp
Stick+Slide τ = µP l p ≤ x ≤ lc

Only Sliding τ = µP 0 ≤ x ≤ lc

Only Sticking τ = τ1 0 ≤ x ≤ lc

120 120

Cutting Force Error - %

sticking+sliding only sliding sticking+sliding only sliding
Feed Force Error - %

100 only sticking 100 only sticking

80 80

60 60

40 40

20 20

0 0
76 152 216 304 606 76 152 216 304 606
Cutting Speed - m/min Cutting Speed - m/min
 Effect of JC on the Force
Predictions
1000 1200

1000
800

Cutting Forces - N
Cutting Forces - N

800
600
600
400
400
200 200

0 0
0.03 0.05 0.07 0.09 0.11 0.13 0.15 0.17 0.05 0.08 0.11 0.14 0.17
Rake=5º feed rate - mm/rev Rake= -5º feed rate - mm/rev

Set A(MPa) B(MPa) n m ν

1 880 500 0.234 0.0134 1
2 553 600 0.234 0.0134 1
3 553 600 0.234 0.0448 1
 Oblique Cutting

Chip flow angle

(A + B )sin η − (2 A C )sin η + 2( A C + CD )sinη
2
1
2
1
4
c 1
3
c 1 c

+ (C − B − 2 A − 2 A D )sin η + (A + D + 2 A D ) = 0
2 2
1
2
1 1
2
c
2
1
2
1
Shear flow angle
tan η s = (tan i cos(φ n − α n ) − tan η c sin φ n ) / cos α n
Turning vs. Orthogonal Cutting

Chip Vc Tool

Workpiece
Vw
FP

FQ

MS 402 Integrated Manufacturing Systems – 2010 SPRING

Turning vs. Oblique Cutting

Vc Chip - flow angle

ηc
Chip

Tool
i

FR

Workpiece

i
90°
Vw FQ
FP

Cutting edge inclination i

MS 402 Integrated Manufacturing Systems – 2010 SPRING

Turning Process Model
Local Cutting Angles

MS 402 Integrated Manufacturing Systems – 2010 SPRING

 Rake Angle
- +
α

α: degrees (radian) - (rake angle / talaş açısı)

MS 402 Integrated Manufacturing Systems – 2010 SPRING

 Rake Angle cont.

Chip
Feed Direction

Workpiece Tool

By definition, the angle between the tool and the radial direction (x axis) is
called rake angle.

MS 402 Integrated Manufacturing Systems – 2010 SPRING

 Inclination Angle
Vc Chip - flow angle
ηc
Chip

Tool
i

FR

Workpiece

i
90°
Vw FQ
FP

Cutting edge inclination i

Cutting
Speed (v)
WP
Inclination
angle (i) b
n
The angle between the tool and the Feed (f)
axial direction (z axis) is called TOOL direction
inclination angle

MS 402 Integrated Manufacturing Systems – 2010 SPRING

 Approach Angle
x

z
y

The angle that tool makes with the

tangential direction is called
approach or side edge cutting angle.
c

MS 402 Integrated Manufacturing Systems – 2010 SPRING

 Side Edge Cutting Angle
(Approach Angle)
F feed = − F f cos(c ) + Fa sin (c )
This image cannot currently be display ed.
Fradial = F f sin (c ) + Fa cos(c )
Ftan = Ft

MS 402 Integrated Manufacturing Systems – 2010 SPRING

 Verification of Cutting Forces
depth=0.2mm
Turning 0.4mm

0.8mm 1.2mm