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Physics based process modeling of serrated chip formation in precision machining of ductile alloys

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TitleInfo
Title
Physics based process modeling of serrated chip formation in precision machining of ductile alloys
Name (type = personal)
NamePart (type = family)
Shah
NamePart (type = given)
Suril Rajivkumar
NamePart (type = date)
1995-
DisplayForm
Suril Rajivkumar Shah
Role
RoleTerm (authority = RULIB)
author
Name (type = personal)
NamePart (type = family)
Ozel
NamePart (type = given)
Tugrul
DisplayForm
Tugrul Ozel
Affiliation
Advisory Committee
Role
RoleTerm (authority = RULIB)
chair
Name (type = personal)
NamePart (type = family)
Luxhoj
NamePart (type = given)
James T.
DisplayForm
James T. Luxhoj
Affiliation
Advisory Committee
Role
RoleTerm (authority = RULIB)
internal member
Name (type = personal)
NamePart (type = family)
Coit
NamePart (type = given)
David W.
DisplayForm
David W. Coit
Affiliation
Advisory Committee
Role
RoleTerm (authority = RULIB)
internal member
Name (type = corporate)
NamePart
Rutgers University
Role
RoleTerm (authority = RULIB)
degree grantor
Name (type = corporate)
NamePart
School of Graduate Studies
Role
RoleTerm (authority = RULIB)
school
TypeOfResource
Text
Genre (authority = marcgt)
theses
OriginInfo
DateCreated (encoding = w3cdtf); (qualifier = exact)
2019
DateOther (encoding = w3cdtf); (qualifier = exact); (type = degree)
2019-05
Language
LanguageTerm (authority = ISO 639-3:2007); (type = text)
English
Abstract (type = abstract)
Ductility 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.
Subject (authority = local)
Topic
Cutting serrated chip formation
Subject (authority = RUETD)
Topic
Industrial and Systems Engineering
Subject (authority = LCSH)
Topic
Metal-cutting
Subject (authority = LCSH)
Topic
Copper
Subject (authority = LCSH)
Topic
Titanium alloys
RelatedItem (type = host)
TitleInfo
Title
Rutgers University Electronic Theses and Dissertations
Identifier (type = RULIB)
ETD
Identifier
ETD_9739
PhysicalDescription
Form (authority = gmd)
InternetMediaType
application/pdf
InternetMediaType
text/xml
Extent
1 online resource (xi, 53 pages) : illustrations
Note (type = degree)
M.S.
Note (type = bibliography)
Includes bibliographical references
RelatedItem (type = host)
TitleInfo
Title
School of Graduate Studies Electronic Theses and Dissertations
Identifier (type = local)
rucore10001600001
Location
PhysicalLocation (authority = marcorg); (displayLabel = Rutgers, The State University of New Jersey)
NjNbRU
Identifier (type = doi)
doi:10.7282/t3-gexh-qg87
Genre (authority = ExL-Esploro)
ETD graduate
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Rights

RightsDeclaration (ID = rulibRdec0006)
The author owns the copyright to this work.
RightsHolder (type = personal)
Name
FamilyName
Shah
GivenName
Suril
MiddleName
Rajivkumar
Role
Copyright Holder
RightsEvent
Type
Permission or license
DateTime (encoding = w3cdtf); (qualifier = exact); (point = start)
2019-04-09 15:51:53
AssociatedEntity
Name
SURIL RAJIVKUMAR SHAH
Role
Copyright holder
Affiliation
Rutgers University. School of Graduate Studies
AssociatedObject
Type
License
Name
Author Agreement License
Detail
I hereby grant to the Rutgers University Libraries and to my school the non-exclusive right to archive, reproduce and distribute my thesis or dissertation, in whole or in part, and/or my abstract, in whole or in part, in and from an electronic format, subject to the release date subsequently stipulated in this submittal form and approved by my school. I represent and stipulate that the thesis or dissertation and its abstract are my original work, that they do not infringe or violate any rights of others, and that I make these grants as the sole owner of the rights to my thesis or dissertation and its abstract. I represent that I have obtained written permissions, when necessary, from the owner(s) of each third party copyrighted matter to be included in my thesis or dissertation and will supply copies of such upon request by my school. I acknowledge that RU ETD and my school will not distribute my thesis or dissertation or its abstract if, in their reasonable judgment, they believe all such rights have not been secured. I acknowledge that I retain ownership rights to the copyright of my work. I also retain the right to use all or part of this thesis or dissertation in future works, such as articles or books.
Copyright
Status
Copyright protected
Availability
Status
Open
Reason
Permission or license
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Technical

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ETD
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windows xp
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1.5
DateCreated (point = end); (encoding = w3cdtf); (qualifier = exact)
2019-04-10T11:06:40
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2019-04-10T11:06:40
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