Study On Modeling of Chip Formation

BDU
BIoT School of Mechanical and Industrial Engineering Manufacturing Engineering Program
Study on Modeling of Chip Formation

For the Partial Fulfillment of the Course of Metal Cutting Theory and Applications
By Wolelaw E.
Instructor: Getye M.
Bahir Dar Novemeber 2011
Presentation Outlines
Introduction Objective Methodology Statement of the problem Literature review Analytical modeling of chip formation Numerical modeling of chip formation Conclusion and Recommendations References
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Introduction
Primary concern in metal cutting is production of chips Chips may constitute fewer to 50% of the initial work piece Removal may differ from product to product From rough to precision work of 0.25 or even less
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BIoT PG in Manufacturing Eng.
1/14/2012
Continued
Chip formation is the heart of metal cutting which needs to be understood It influences power requirement, tool life, work quality and efficiency Attempts were made in the past to understand the process by modeling This paper tries to review past experience in modeling chip formation based on bibliographic study
Objective
To review theoretical backgrounds and models of chip formation
Methodology
Literature review on the subject General overview is only treated
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Statement of problem
Chip shape and size varied widely in machining operations. Poor surface finish, work piece accuracy Short tool life Low productivity
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Literature review
The single shear plane model was analyzed by Merchant in 1945 Palmer and Oxley (1959) developed a thick-zone chip formation model They studied metal cutting at low speed and derived slip line field using modified Hencky relationship Oxley (1961) developed another thin shear model which assumes none uniform stress at the rake face of tool
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Continued
Okushima and Hitomi (1961) made the other analysis of thick zone model chip formation This analysis is complex with requiring more assumptions Klamecki (1973) developed finite element modeling based on single shear plane Later different investigators modified and powerful soft wares are commercially available in the market.
Analytical Modeling of Chip Formation

Evolves from observation Quick Stop Micro level pictures (Photomicrographs)
Fig.1 Early observations on chip formation

Continued
Orthogonal cutting Straight tool edge Normal to direction of cutting and feed
Fig. 2 Chip formation model

Continued
Fig. 3 Force circle diagram

Continued
V- Velocity of work piece VS- Shear velocity VC- Chip velocity Fig. 4 Velocity diagram
Continued
Fig. 4 Shear strain

Numerical Modeling of Chip Formation

Analytical modeling methods have limited applications Numerical methods came up to address this problem FEM is now gaining acceptance in modeling chip formation Material property, tool property, temperature, cutting fluid, tool material interface could be imposed
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Continued
It is based on dividing a continuum systemdescribe element properties as matricesassemble them- this gives the behavior of the system While FEM is very powerful, the result will be only as good as the properties fed in
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Continued
2D Machining
Cutting tool Work piece
Fig. 5 Chip formation modeling in two dimensional machining

Continued
Kinematic and thermal constraints are induced in this analysis Other chip formation factors are also imposed
Fig. 6 Study areas in 2D FEM modeling of chip formation Mechanical and thermal boundary conditions (Source: P.J. Arrazola et.al 2oo5)
Conclusion and Recommendation

Current modeling methods are not capable of
predicting chip formation

This is mainly because the modeling methods are
based on the oversimplified orthogonal cutting method

Chip formation is a complicated process taken place
within a short period requiring determination of several parameters

Continued
A diversity of physical phenomenon exists at the process zone due to different systems Result of system interaction Interaction effects are even complex Studying past experience, understanding the system and its interaction and looking for new options is important
References
[1] CENK KILIASLAN. MODELLING AND SIMULATION OF METAL CUTTING BY FINITE ELEMENT METHOD. A Thesis Submitted to the Graduate School of Engineering and Sciences of zmir Institute of Technology in Partial Fulfillment of the Requirements for the Degree of MASTER OF SCIENCE in Mechanical Engineering. 2009. [2] DeGarmo, E. Paul. Materials and Processes in Manufacturing 2nd edition. Macmillan Publishing Co. Inc. 1974. [3] Edward M. Trent and Paul K. Wright. Metal Cutting 4th edition. ButterworthHeinemann.2000. [4] P.J. Arrazola et al. Finite element modeling of chip formation process with ABAQUS/EXPLICITTM 6.3. VIII International Conference on Computational Plasticity. COMPLAS VIII E. Oate and D. J. Owen (Eds) CIMNE, Barcelona, 2005. [5] Shaw, Milton C. Metal Cutting Principles. Oxford Series on Advanced Manufacturing, 1996. [6] Vahid Kalhori. Modeling and Simulation of Mechanical Cutting. Ph. D Thesis, Lule University of Technology, Sweden, 2001. [7] Viktor P. Astakhov. On the inadequacy of the single-shear plane model of chip formation. International Journal of Mechanical Sciences 47 (2005) 16491672. [8] Viktor P. Astakhov and S.V. Shvets. A system concept in metal cutting. Journal of Materials Processing Technology 79 (1998) 189199. [9] V.P. Astakhov , M.O.M. Osman, M.T. Hayajneh. Re-evaluation of the basic mechanics of orthogonal metal cutting: velocity diagram, virtual work equation and upper bound theorem International Journal of Machine Tools & Manufacture 41 (2001) 393418.
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Thank you
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BDU

BIoT School of Mechanical and Industrial Engineering Manufacturing Engineering Program

Study on Modeling of Chip Formation

Bahir Dar Novemeber 2011

BIoT PG in Manufacturing Eng.

BIoT PG in Manufacturing Eng.

BIoT PG in Manufacturing Eng.

BIoT PG in Manufacturing Eng.

Analytical Modeling of Chip Formation

Fig.1 Early observations on chip formation

Fig. 2 Chip formation model

Fig. 3 Force circle diagram

Fig. 4 Shear strain

Numerical Modeling of Chip Formation

BIoT PG in Manufacturing Eng.

BIoT PG in Manufacturing Eng.

Fig. 5 Chip formation modeling in two dimensional machining

Conclusion and Recommendation

predicting chip formation

based on the oversimplified orthogonal cutting method

within a short period requiring determination of several parameters

BIoT PG in Manufacturing Eng.

BIoT PG in Manufacturing Eng.

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