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Finite Element Simulation of Metal Cutting of Aluminum using Johnson-Cook Damage Model and Shear Failure Model.

Article

Last updated: 22 Jan 2023

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Tags

Mechanical Power Engineering

Abstract

This paper evaluates the use of the Johnson-Cook (J-C) damage model and the shear failure model in the Finite Element metal cutting simulations of an Aluminum alloy (Al 1100) using an FE commercial package ABAQUS. For the J-C model, the damage evolution in the model is controlled by the value of the parameter "equivalent plastic displacement at failure",  . The value of this parameter is provided to ABAQUS by user. It was found that the value of that parameter, in conjunction with mesh size, highly affects the chip morphology, chip ratio and analysis completion. Therefore, a compromising between the value of and the mesh size used should be done. The proper value of the  depends on the mesh size in the chip zone of the model. Therefore, it is suggested to select the element size, of chip zone of the model, almost equals to the average grain size of workpiece. Then, change the values of  until the obtained FE results agree well with experimentally formed chip. As an alternative to the use of J-C damage model, shear failure model was also used. The use of the shear failure model does not need a definition of a damage parameter to conduct the cutting simulations. The results obtained from the J-C damage model, with tuned , are in good agreement with those obtained using the shear failure model. However, those results are meshing dependent in both models. Therefore, qualitative comparison of the simulated chip with experimental chip is still necessary.

DOI

10.21608/bfemu.2020.90303

Keywords

Finite element method, Metal cutting, Simulation, chip formation, ductile damage model, shear failure model, Al 1100

Authors

First Name

Mohammed

Last Name

Saber

MiddleName

Elsaid

Affiliation

Assistant Professor at the Department of Production Engineering and Mechanical Design, Faculty of Engineering, Port Said University, Port Fouad, Port Said, Egypt

Email

mssaber77@yahoo.com

City

Port Said

Orcid

-

First Name

Mohamed

Last Name

El Sheikh

MiddleName

Yousry Mahmoud

Affiliation

Structural Engineering Dept. – Faculty of Engineering – Mansoura University

Email

mohamed_elshikh@mans.edu.eg

City

Mansoura

Orcid

-

First Name

Mahmoud

Last Name

Dawoud

MiddleName

Hussieny Ahmed

Affiliation

Structural Engineering Dept. – Faculty of Engineering – Mansoura University

Email

-

City

Mansoura

Orcid

-

Volume

42

Article Issue

2

Related Issue

13234

Issue Date

2017-06-01

Receive Date

2016-09-28

Publish Date

2020-05-18

Page Start

34

Page End

40

Print ISSN

1110-0923

Online ISSN

2735-4202

Article File

BFEMU_Volume 42_Issue 2_Pages 34-40.pdf

PDF . 470.6kB

Link

https://bfemu.journals.ekb.eg/article_90303.html

Detail API

https://bfemu.journals.ekb.eg/service?article_code=90303

Order

11

Type

Research Studies

Type Code

1,205

Publication Type

Journal

Publication Title

MEJ. Mansoura Engineering Journal

Publication Link

https://bfemu.journals.ekb.eg/

MainTitle

-

Details

Type

Article

Created At

22 Jan 2023