3D FEM Model for the Prediction of Chip Breakage

Fritz Klocke; Dieter Lung; Christoph Essig

doi:10.4028/www.scientific.net/AMR.223.142

Paper Titles

Analytical Model of Chip Formation in Case of Orthogonal Cutting Processes
p.101

CFRP Drilling Model: Fiber Orientation Influence on Mechanical Load and Delamination
p.111

Numerical Model for Prediction of Cutting Force in Peripheral Milling Process Including Thrust and Tangential Damping
p.122

FEM Based Design of a Chip Breaker for the Machining with PCD Tools
p.133

3D FEM Model for the Prediction of Chip Breakage
p.142

A Numerical and Experimental Investigation of the Deformation Zones and the Corresponding Cutting Forces in Orthogonal Cutting
p.152

On Methodologies inside Two Different Commercial Codes to Simulate the Cutting Operation
p.162

Application of the Nodal Integrated Finite Element Method to Cutting: a Preliminary Comparison with the “Traditional” FEM Approach
p.172

Validation of Finite Element Modeling of Drilling Processes with Solid Tooling in Metals
p.182

HomeAdvanced Materials ResearchAdvanced Materials Research Vol. 2233D FEM Model for the Prediction of Chip Breakage

3D FEM Model for the Prediction of Chip Breakage

Abstract:

The aim of the presented work was to define a criterion for the prediction of chip breakage in turning C45E+N (AISI 1045). The chip formation, the chip flow and the expansion of the chip due to collision with the periphery were modelled three-dimensionally using the Finite Element Method (FEM). The mechanical loads in the chip breakage zone were determined by comparing the modelled chip with high speed filming records of the real chip breakage cycle. Based on the calculated loads in the chip breakage zone a novel damage criterion based on an approach of Johnson and Cook was developed. This criterion enables the FEM-model to simulate chip breakage three-dimensionally for different tool geometries and varying cutting parameters. The enhanced FE model correlated well with high speed filming records of the chip flow and breakage as well as with the empirical determined cutting forces and chip temperatures.

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Periodical:

Advanced Materials Research (Volume 223)

Pages:

142-151

DOI:

https://doi.org/10.4028/www.scientific.net/AMR.223.142

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Online since:

April 2011

Authors:

Fritz Klocke, Dieter Lung, Christoph Essig

Keywords:

AISI 1045 (C45E+N), Chip Breakage, Damage Model, Finite Element (FE) Simulation, Material Damage

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