Development and verification of a constitutive approach for the determination of high-speed flow curves by means of the cutting process

Steckbrief

Eckdaten

Duration:
01.01.2018 to 31.12.2019
Organizational Unit:
Chair of Manufacturing Technology, Cutting Technology
Funding:
German Research Foundation DFG
Status:
Closed

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Compared to the conventional empirical process design based on experimental cutting tests, the simulation-based process development and design offers the potential to reduce the development time and costs of cutting processes. To model the machining process different input models are necessary. In addition to the friction model, which describe the mechanical interaction between the tool and the workpiece as well as the tool and the chip, thermal models and material models are required. The determination of material models poses great challenges for modeling of machining processes due to the thermo-mechanical load occurring in the process. This is due to the fact that the strains, strain rates and temperatures in the machining process can only be represented insufficiently by conventional material tests.

Therefore, this research project pursues an inverse approach in which a methodology for determining parameters of material models is developed by means of FEM chip formation simulation. For this purpose, the cutting force components, cutting temperatures and fields as well as the chip shape and formation determined from experimental orthogonal cutting tests are used as validation parameters for the FEM chip formation simulation. By a comparison between experimentally and simulatively determined parameters, the material model as well as the determined parameters can be assumed as valid if there is a sufficiently good agreement.