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Physics based process modeling of serrated chip formation in precision machining of ductile alloys
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Shah, Suril Rajivkumar. Physics based process modeling of serrated chip formation in precision machining of ductile alloys. Retrieved from https://doi.org/doi:10.7282/t3-gexh-qg87

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TitlePhysics based process modeling of serrated chip formation in precision machining of ductile alloys
NameShah, Suril Rajivkumar (author); Ozel, Tugrul (chair); Luxhoj, James T. (internal member); Coit, David W. (internal member); Rutgers University; School of Graduate Studies
Date Created2019
Other Date2019-05 (degree)
SubjectCutting serrated chip formation, Industrial and Systems Engineering, Metal-cutting, Copper, Titanium alloys
Extent1 online resource (xi, 53 pages) : illustrations
DescriptionDuctility of the material can be defined as a limit until which a material can be plastically deformed without fracture. Ductile metals and alloys have the ability to withstand the deformation in their specific plastic region. Some of the common ductile metals are aluminum, copper, nickel, titanium and silver. Precision cutting of these metals has wide ranging applications in industry, however it presents challenges due to formation of serrated chips and resulting in process irregularities and instabilities. In this research, specially designed orthogonal cutting tests are utilized on copper 10100 and titanium alloy Ti6Al4V at meaningful combination of cutting conditions (feed, speed and depth of cut). Formation of serrated and segmented chips from these experiments are investigated with digital optical microscopy to study morphology and degree of serration. An analytical model is developed to calculate shear stress, shear strain, and shear strain rate from the measured forces and chip dimensions. Finite element (FE) simulations are designed to compare the simulated output data (forces, stress, strain) with the analytical model and the experimental data. Specifically, constitutive material modeling using Johnson-Cook model, flow softening and/or ductile failure are employed where suitable in FE simulations. We developed a methodology to identify a proper set of Johnson-Cook material constitutive model parameters, flow softening behavior, failure and damage models for the purpose of simulating serrated chip formation process in orthogonal cutting conditions. It is demonstrated that, segmentation of chip, cutting forces, shear stress and shear strain rate can be predicted from the simulations of the machining process rather than conducting actual experiments.
NoteM.S.
NoteIncludes bibliographical references
Genretheses, ETD graduate
Persistent URLhttps://doi.org/doi:10.7282/t3-gexh-qg87
LanguageEnglish
CollectionSchool of Graduate Studies Electronic Theses and Dissertations
Organization NameRutgers, The State University of New Jersey
RightsThe author owns the copyright to this work.
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