Professional Documents
Culture Documents
processes
Simulation Techniques in Manufacturing Technology
Lecture 8
Laboratory for Machine Tools and Production Engineering
Chair of Manufacturing Technology
Outline
1
Introduction
WZL/Fraunhofer IPT
Seite 2
Workpiece material
structure
Cutting zone
chip forming
mechanisms
texture
mechanical
properties
hardness
residual stresses
WZL/Fraunhofer IPT
Tool
cutting material
Machine
machine design
coating
cooling lubricant
geometry
cutting parameters
contact
conditions
e.g.: friction, wear
heat transfer
drive system
M
tool holder
clamping device
Seite 3
Strain
Thomolog
Extrusion
25
10-1 10-2
0.16 0.7
Forging /
Rolling
0.1 0.5
10 10+3
0.16 0.7
Sheet metal
forming
0.1 0.5
10 10+2
0.16 0.7
Cutting
15
10+3 10+6
0.16 0.9
Cutting process
Seite 4
Outline
1
Introduction
WZL/Fraunhofer IPT
Seite 5
process
Modelling of the thermo mechanical material behavior for the entire temperature and
Seite 6
Component / tool
Geometry
Material data
Contact conditions
Boundary conditions
Cutting conditions
WZL/Fraunhofer IPT
Tool
Strain
Tension
Temperature
Cutting forces
Wear
Component
Strain
Temperatures
Deformation
Burr formation
Distortion
Future:
Residual stresses
Surface quality, e.g.: roughness,
changes in shape,
Measurement and position
Seite 7
Outline
1
Introduction
WZL/Fraunhofer IPT
Seite 8
major
Hauptschneide
cutting edge
Querschneide
chisel edge
flank
Freiflface
che
a = 10
d = 35
HW-K20
DK = 0.5 0.7 m
Seite 9
WZL/Fraunhofer IPT
Seite 10
FEM-model
CAD-model
Macro
geometry
4 mm
Micro
geometry
6 m
WZL/Fraunhofer IPT
6 m
Seite 11
Outline
1
Introduction
Summary
Zusammenfassung
and Outlook
und
Zusammenfassung
und Ausblick
Ausblick
WZL/Fraunhofer IPT
Seite 12
Bi u i
WZL/Fraunhofer IPT
Seite 13
s s ( , , T )
Strain Hardening
450
Thermal Softening
450
450
-3 -1
s , MPa
400
400
300
350
150
-1
350
300
250
AA6063-T6
200
0.1
Quelle: Diss-Abouridoaune
WZL/Fraunhofer IPT
0.2
, -
AA6063-T6
0.3
0.4
300
-3
10
AA6063-T6
0
-1
10
10
d/dt , s
10
-1
100
200
300
400
500
T , C
Seite 14
T Tr
s (A B ) (1 C ln( / 0 )) (1
)
Tm Tr Thermal softening
Strain hardening
kT
0
s sa s 1
ln
G 0
*
0
Athermal processes
Damping process
Initial density
of dislocations
Source: Diss-Abouridouane
WZL/Fraunhofer IPT
Influence of temperature
and strain rate
Dislocation jam
TemperierTemperature
chamber
kammer
Eingangsstab
Input rod
Output
rod
Ausgangsstab
Tube
Rohr
Bearing
Lager
Air cylinder
Preluftbehlter
Joke
Joch
Rohr
Tube
Sample
Probe
Projectile
Projektil
Deckel mit
Cover with air
Luftanschluss
Eingangsstab
Input rod
Tensile
specimen
Zugprobe
Geweda
Prof. El-Magd
Ausgangsstab
Output
rod
Lager
Bearing
Pressluftbehlter
Air cylinder with mit
Schnellffnungsventil
quick release valve
WZL/Fraunhofer IPT
Auffangbehlter
Collection
bag
Split-Hopkinson-Tension-Bar
connection
Source: LFW
Bearing
Lager
Bearing
Lager
Strain rate:
Temperature range:
93 K 1273 K
Projectile speed:
Projectile mass:
m = 3,15 kg
Seite 16
K B
1 a K ( B )n dt
n
ad
800
True
w
SpannungMPA
, MPa
ahreStress,
kf
AA7075 T7351
DPressure
ruckversutests
che
K = 960 MPa
B = 0.031
n = 0.182
-6
/ K = 6.2510 s
700
d / dt =-1
5010 s-1
4889 s-1
4350 s-1
4294 s-1
3450 s-1
3439 s-1
2558 s-1
2529 s -1
0.001 s
600
500
400
0.2
Lines: Calculation
Symbols:
o experiments
:
r
0.4
0.6
0.8
Source: Diss-Brodmann
WZL/Fraunhofer IPT
Seite 17
Outline
1
Introduction
WZL/Fraunhofer IPT
Seite 18
Failure mechanisms
Loading type
Tensile stress
Shear stress
TiAl6V4
20 m
20 m
Source: Diss-Abouridouane
WZL/Fraunhofer IPT
Seite 19
dD
D = v,f / D = v,f
DGosh = (1+2/1) 12
= (m/v) dv
s0
E
3 m
f = n + exp
2 v
Gurson-Tveergard-Needleman-Model
Johnson-Cook-Model
Source: Diss-Abouridouane
WZL/Fraunhofer IPT
V
3 m
2
0=
+
2fq
cosh
1+
q
f
1
1
2
V,M
V,M
m
T
f = D1 + D2exp -D3
1+ D4ln 1+ D5
v
m
0
Seite 20
1.0
1.0
f = 0.05+2.89*exp(-2.35*sm/sv)
f = 0.05+2.33*exp(-2.49*sm/sv)
0.8
0.8
glatt
r = 1.2 mm
r = 0.8 mm
r = 0.4 mm
r = 0.02 mm
0.6
0.4
0.6
0.4
0.2
TiAl6V4, = 20C
quasistatisch
0 quasi-static
0
0.5
1.5
0.2
1.5
TiAl6V4, = 200C
quasistatisch
0 quasi-static
0
0.5
1.0
2.0
2.5
f = 0.09+5.2*exp(-2.35*sm/sv)
1.5
2.0
1.0
1.5
1.0
2.0
2.5
glatt
r = 1.2 mm
r = 0.8 mm
r = 0.4 mm
r = 0.02 mm
0.5
TiAl6V4, = 200C
dynamisch
dynamic
0
1.5
0.5
f = 0.09+3.54*exp(-2.61*sm/sv)
glatt
r = 1.2 mm
r = 0.8 mm
r = 0.4 mm
r = 0.02 mm
0.5
WZL/Fraunhofer IPT
TiAl6V4, = 20C
dynamisch
dynamic
0
1.0
1.0
Source: Diss-Abouridouane
glatt
r = 1.2 mm
r = 0.8 mm
r = 0.4 mm
r = 0.02 mm
2.5
0.5
1.0
1.5
2.0
2.5
Mehrachsigkeit
Multiaxiality sm/sv
Seite 21
Geometrical separation
Geometrischen Trennkriterium
Physikalisches Trennkriterium
criterion
Geometrischen Trennkriterium
Physikalisches Trennkriterium
As
Span
Chip
X
Hs,w
Bs
Span
Cs
vc
As
Bs
As
Trenn-I
Trennkriterium Separation
Bs
kriterium
criterion
dcr
d
separation criterion
As
Bs
v
c
Cs
Cs
vc IKR
vc
IKR D
Ds
s
Werkzeug
Werkzeug
Tool
Ds
Ds
Es
Werkzeug
Werkzeug
Tool
Es
Fs
E
s
Es
X X
X
Fs
XGX F
D
GX
F
E
C
B
D
H
E
C
B
w
s,w
s,w
w
w
w
w
w
w
Dw Cw Bw s,w s,w wHs,w G
H
Ew wDw Cw Bw
s,w Gs,w Fs,w Ew
s,w Fw
Cs
plane
Schnittebene
dcr Sectional
Schnittebene
d
Without a specific
Distorted grid
topology
New networked
grid topology
Tool
Tool
Schnittebene
Schnittebene
WZL/Fraunhofer IPT
an defined, maximum
equivalent stress or at
predefined maximum
tensions
Separation through
Seite 22
New Mesh
a)
Span
Chip
Werkzeug
Tool
b)
New Mesh
WZL/Fraunhofer IPT
Seite 23
Tension
Compression
Microstructure
Macrostructure
RVE
900
Two-phase 3D FE model
Cross section
0.1x0.1 mm
Compression stress
FE model
600
Shear
Shear stress
Experiment
300
Longitudinal section
Quasi-static
0.1x0.1x0.1 mm
0.5
1.0
1.5
2.0
Pearlite
WZL/Fraunhofer IPT
Ferrite
Seite 24
20
Ferrite
Pearlite
10
3%
20
Nmm
16
Test 7% 19% 12
Isotropic model
30
Torque
Mixture model
Chip
50 Feed force
N
40 22% Test
Mixture model
Drill
Isotropic model
Microstructure
0
0
d = 1 mm, vc = 35 m/min, f = 12 m
Drill
Workpiece
Holes
Workpiece
WZL/Fraunhofer IPT
Chip form
Seite 25
Thermal
state
Thermally-induced phase
transformation
Metallurgical
state
Heat gain
Residual stresses
Mechanical
State
The complete coupling of the various parameters influencing the formation of residual
Seite 26
Koistenen-Marburger-relation, 1959
TTT/TTA-diagram for not isotherm conditions (high strain rate)
Thermal material properties, depending on temperature (cp, l r )
Seite 27
Outline
1
Introduction
WZL/Fraunhofer IPT
Seite 28
vc
380 C
130
80
500
30
600
650
Tool flank
Cutting surface
600
Cutting edge
1
2
3
4
5
Tool
Primary shear zone
Secondary shear zone at rake face
Jam and separation zone
Secondary shear zone at flank face
Run-up deformation zone
WZL/Fraunhofer IPT
Material:
Elastic limit:
Cutting material:
Cutting velocity:
Chip thickness:
Rake angle:
310
chip
400
450
500
700
tool
steel
kf = 850 N/mm2
HW-P20
vc = 60 m/min
h = 0,32 mm
o = 10
Seite 29
Shear edge
vc
Structure in
the chip
Shear zone
5
0,1 mm
1
3
4
Tool flank
Cutting surface
Cutting edge
1
2
3
4
5
Tool
Primary shear zone
Secondary shear zone at rake face
Jam and separation zone
Secondary shear zone at flank face
Run-up deformation zone
WZL/Fraunhofer IPT
Turning tool
Cutting edge
Material:
Cutting material:
Cutting velocity.:
Chip section:
C53E
HW-P30
vc = 100 m/min
ap x f = 2 x 0,315 mm2
Seite 30
vc
Structure
in the chip
5
3
Cutting edge
Tool
Primary shear zone
Secondary shear zone at rake face
Jam and separation zone
Secondary shear zone at the flank face
Run-up deformation zone
WZL/Fraunhofer IPT
Shear stress:
Tool flank
Cutting surface
1
2
3
4
5
Normal stress:
Contact zone
Tool
Seite 31
reality
R m k
with
kf
3
Dynamic friction
Static friction
sN
Usiu
Shaw /
Wanheim and Bay
sN
WZL/Fraunhofer IPT
Z.B.: Usui-model
= 1 exp( )
Orowan / zel
reality
sN
normal stress
kf
, m
friction coefficients
Seite 32
Chip
Tool
Crater wear
Edge chippage
Cutting
edge
Crater wear
Flank
Flank abrasion
Built-up edge
Flank wear
Workpiece
Oxidation notch
Sliding mechanisms
Abrasion
WZL/Fraunhofer IPT
Adhesion
Delamination
Not-gliding mechanisms
Diffusion
electrochemical
Oxidation
Seite 33
Differential
wear models
T v ck Cv
T = tool life
u = temperature
k, A, B = constant
Cv = T fr vc = 1 m/min
Adhesion
Abrasion + Diffusion
Adhesion / dV
F S
K
Abrasion
dt
3H
dV/dt:
H:
F:
S:
WZL/Fraunhofer IPT
( 2 )
dV
n v ch C1 e T
dt
wear-volume-rate
hardness
mechanical load
cutting length
E
dV
G v c D e R
dt
K, C1, C2, G, D:
constant
sn:
normal stress
Vch:
chip sliding speed
u:
temperature
Seite 34
Tool
Workpiece
2D FEM Cutting Model
WZL/Fraunhofer IPT
Seite 35
Friction
Heat Transfer
Tool
Movement
=
Object 1
Workpiece = Object 2
2D FEM Cutting Model
WZL/Fraunhofer IPT
Seite 36
Boundary conditions
Boundary Conditions
Self Contact (Chip vs. Workpiece Surface)
Object Conditions
Friction
Heat Transfer
FN
Movement
FR
Seite 37
Object Conditions
Tool is fixed in x- and y-direction!
Friction
Heat Transfer
Tool
Movement
Cutting
speed vc in
x-direction
Workpiece
WZL/Fraunhofer IPT
Seite 38
Object Conditions
Heat Transfer
Friction
Heat Transfer
Movement
Workpiece
WZL/Fraunhofer IPT
Seite 39
Object Conditions
Friction
Heat Transfer
Tool
FN
FN
Heat Transfer
FR
FN
WZL/Fraunhofer IPT
Seite 40
Heat Transfer
Tool
Heat Convection
Heat Emissivity
Heat Radiation
Heat Convection
Seite 41
Outline
1
Introduction
WZL/Fraunhofer IPT
Seite 42
MSC.Marc
WZL/Fraunhofer IPT
Seite 43
ABAQUS
ANSYS/ LS-DYNA
AdvantEdge
DEFORM
COMSOL
Criteria
Creation of geometries
Creation of geometries
and import of CAD data
Creation of simple
geometries and
import of CAD data
Creation of simple
geometries and
import of CAD data
Creation of simple
geometries and import
of CAD data
Material catalogue
Yes, expandable
Yes, wide
yes
Element type
Every type
Every type
tetrahedron,
rectangle
tetrahedron, rectangle
Every type
Time integration
Implicit / Explicit
Implicit / Explicit
Explicit
Implicit
Implicit
Remeshing routine
none
none
yes
yes
yes
use
general
general
cuttingprocess
Deforming process
general
Influence on simulation
computation
High, by Python
Possible, by Fortran
no
High, by Fortran
High, by Matlab
parallelisation
possible
possible
possible
possible
possible
Eigenfrequency analysis,
elast. Tool behavior,
elasto-plastic component
behavior
no
no
Cutting simulation
Thermo-elastic
deformation
Seite 44
Outline
1
Introduction
WZL/Fraunhofer IPT
Seite 45
Milling
Turning
WZL/Fraunhofer IPT
Seite 46
vc
WZL/Fraunhofer IPT
Seite 47
WZL/Fraunhofer IPT
Seite 48
WZL/Fraunhofer IPT
Seite 49
WZL/Fraunhofer IPT
Seite 50
WZL/Fraunhofer IPT
Seite 51
WZL/Fraunhofer IPT
Seite 52
WZL/Fraunhofer IPT
Seite 53
Ceramic-Insert
Thermal conductivity l = 35 W/mK
Tmax = 650C
WZL/Fraunhofer IPT
WC-Insert
Thermal conductivity l = 105 W/mK
Tmax = 550C
Seite 54
Tsp
TiN
570
6 m
Calculated temperature at the
chip bottom side TSp / C
3 m
6 m
557
560
550
539
540
539
533
530
520
509
510
Al2O3
0
Coating
Thickness
TiN
3 m
TiN
6 m
Heat conductivity:
HW:
100 W/(mK)
TiN:
26,7 W/(mK)
Al2O3: 7,5 W/(mK)
HW
TiN
6 m
Al2O3
6 m
Heat capacity:
HW:
3,5 J/(cmK)
TiN:
3,2 J/(cmK)
Al2O3: 3,5 J/(cmK)
Material: C45E+N
Cutting Material: HW-K10/20
Tensile strength: Rm = 610 N/mm
WZL/Fraunhofer IPT
Seite 55
Wear curve
Machining experiments
120
vc = 200 m/min
vc = 150 m/min
Verschleimarkenbreite VB [m]
Tool-wear VB
vc = 250 m/min
100
80
t = 10 min
t = 6 min
t = 4 min
t = 1 min
60
40
20
0
0
10
15
20
25
Cutting time t
30
35
40
Schnittzeit t [min]
dW
n v ch C1 e
dt
C
( 2 )
T
lg C1
lg {w /( sn VS)}
Determination of the
specific material
parameters C1 and C2
dW/dt
Regression analysis
FE-analysis
Temperature
Normal-
C2
tension
Sliding speed
1/T
WZL/Fraunhofer IPT
Seite 56
Verschlei VB [mm]
WZL/Fraunhofer IPT
Tool life
Seite 57
square element
Tool
Workpiece
vc
Rake
Chip
vc
WZL/Fraunhofer IPT
Seite 58
node
square element
5 m
nB
nA
A
Workpiece
WZL/Fraunhofer IPT
Tool
nC
C
nD
Flank
D
nA = nB = nC = nD
Seite 59
[mm]
Flank
wear
VB [mm]
Width VB/
Wearwidth
Flank
Time:
5 min
a0 = 7
Time:
15 min
Time:
25 min
Time:
35 min
93 m
0,1
Experiment
0,08
0,06
Simulation
0,04
0,02
0
0
10
15
20
25
30
35
Cutting
time t [min]
Time [min]
WZL/Fraunhofer IPT
Seite 60
Setup of a 3D FE model
15
15
7,5
WZL/Fraunhofer IPT
Seite 61
Kennametal
ID: PCLNL252M12 F4 NG27
Rake angle 0 = -6
Relief angle a0 = 6
Tool inclination angle ls = -6
Rotx=-6
WZL/Fraunhofer IPT
Seite 62
tool
ap
r
WZL/Fraunhofer IPT
tool
=r
workpiece
workpiece
Seite 63
WZL/Fraunhofer IPT
Seite 64
3D simulation
Workpiece: AISI 1045
Tool: K10
vc = 300 m/min
f = 0,1 mm
Temperature
Cutting Force Fc
WZL/Fraunhofer IPT
Seite 65
WZL/Fraunhofer IPT
Seite 66
WZL/Fraunhofer IPT
Seite 67
WZL/Fraunhofer IPT
Seite 68
Strain Rate
Strain Rate
distribution
For better visualization
WZL/Fraunhofer IPT
Seite 69
Roughing geometry
CNMG120408RN
WZL/Fraunhofer IPT
Finishing geometry
CNMG120408FN
Seite 70
Chip breaker RN
Material:
C45E+N
Cutting material:
HC P25
Insert:
CNMG120408
Insert geometry:
a0 0
lS
6 -6 -6 95 90
Cutting velocity.:
vc = 300 m/min
Feed:
f = 0,1 mm
Depth of cut:
ap = 1 mm
Dry cutting
WZL/Fraunhofer IPT
Seite 71
Chip breaker RN
Material:
C45E+N
Cutting material:
HC P25
Insert:
CNMG120408
Insert geometry:
a0 0
lS
6 -6 -6 95 90
Cutting velocity.:
vc = 300 m/min
Feed:
f = 0,1 mm
Depth of cut:
ap = 1 mm
Dry cutting
WZL/Fraunhofer IPT
Seite 72
ap = 1,9 mm
f = 0,25 mm
vc = 200 m/min
dry
vf
WZL/Fraunhofer IPT
vc
Seite 73
drill
f Bohrwerkzeug
Friction
Reibung
Reibung
Friction
Workpiece
Werkstck
Plastic
Plastische
Verformung
deformation
WZL/Fraunhofer IPT
Stofftrennungof material
Separation
Seite 74
s s(, , T)
FE boundary conditions
FEM-Model
Strain hardening
Cutting parameters
Plasticity
Damping mechanism
Friction law
Relaxation
Heat transfer
Element size
Temperature influence
Number of elements
Loss of cohesion
Remeshing strategy
Failure mechanism
Degree of freedom
WZL/Fraunhofer IPT
Seite 75
C45E+N
HW-K20
35 m/min
0.012 mm/U
133 mm/min
none
Boundary Conditions
Tool:
rigid
number of elements: 90 000
Workpiece:
visco-plastic (LFW-material law),
temperatur fixed at boundary nodes
number of elements: 100 000
Contact:
coulomb friction ( =0,2)
heat transfer (conduction & convection)
Computing time and drilling depth:
2000 h; 0.18 mm (70% of the major cutting edge)
WZL/Fraunhofer IPT
Seite 76
Workpiece material:
C45E+N
HW K20
Feed:
WZL/Fraunhofer IPT
f = 0.012 mm
Seite 77
2]
spezifische
kf,max [kN/mm
]
force kf,max [kN/mm
feedVorschubkraft
Specific
32
Workpiece:
C45E+N
30
28
26
Cutting speed:
vc = 35 m/min
24
22
20
9 10
Durchmesser d [mm]
Diameter d [mm]
Feed:
f = 0,012 * d
Cutting tool material:
HW-K20
2
Experiment
Simulation
kf,max = 2 * Fz,max / (d * f)
0
WZL/Fraunhofer IPT
4
5
6
7
DrillBohrerdurchmesser
diameter d [mm] d [mm]
10
Corner radius:
rn = 4 m
Cooling:
None
Seite 78
Temperature at the
major cutting edge T [C]
400
Experiment
Simulation
d = 3 mm
300
200
100
0
1
10
Diameter d [mm]
Cutting speed:
Feed:
Coolant:
WZL/Fraunhofer IPT
vc = 35 m/min
f = 0,012 * d
None
Workpiece:
C45E+N
Cutting tool material:HW-K20
Rounding:
rn = 4 m
Seite 79
Tool material:
Coated WC
Cutting parameters:
No. of teeth:
z=4
Diameter:
D = 32 mm
Engagement angle:
A E = 180
Feed:
f = 0.5 mm
fZ = 0.125 mm
Depth of cut:
ap = 0.8 mm
r = 90
= -5
No. of rev.:
n = 2250 min-1
WZL/Fraunhofer IPT
Tool
r
ap
Workpiece
Seite 80
axial = 9
radial = 5
axial
WZL/Fraunhofer IPT
Seite 81
Feed f
Workpiece geometry
tool
= r Workpiece
r Tool
View
ap
r Workpiece
WZL/Fraunhofer IPT
Seite 82
WZL/Fraunhofer IPT
Seite 83
work piece
Simulation of chip formation
back
WZL/Fraunhofer IPT
Seite 84
WZL/Fraunhofer IPT
Right
Seite 85
WZL/Fraunhofer IPT
Seite 86
Simulation
Full agreement
WZL/Fraunhofer IPT
Seite 87
Goal output
parameters:
Heat capacity
Thermal conductivity
Cutting force Fc
Passive force Fp
Flow stress
Feed force Ff
Friction coefficient
Temperature T
Tool micro-geometry
Legend
Influence
Heat
capacity
Thermal
conductivity
Flow
stress
Tool
micro-geometry
Friction
Cutting force
low
Feed force
medium
Passive force
high
WZL/Fraunhofer IPT
Temperature
Seite 88
Outline
1
Introduction
WZL/Fraunhofer IPT
Seite 89
Outlook:
Benchmark-Analysis to choose the best tool geometry
Fixed input
parameter
material parameter,
friction coefficients
Cutting parameter 2
vc2, ap1, f1
+
Tool
B
Determination of the
thermomechanical
loadspectrum, chip
flow, chip form
Temp
+
Coating
TiN TiAlN AlO2
WZL/Fraunhofer IPT
Flank wear VB
Q,
T,
Fi,
Cutting parameter
1
2
Cutting parameter 1
vc1, ap1, f1
Benchmark-Analysis
Cutting
simulation
Wear
B
Tool
Stress
Chip
flow
Tool A
++
Tool B
--
Tool C
++
++
Optimised
tooland
tool carriergeometry
Seite 90
Summary
Machining process: System of complex physically coherent operations
A holistic and comprehensive simulation of the machining has not been achieved with
Seite 91
Questions
What are the ranges of temperature, strain and strain rate in cutting operations?
What is the range of strain rate, that can be realized by the Split-Hopkinson-Bar-Test?
Name two friction models. What are the advantages and the disadvantgeas of these
models?
How is the strain rate effecting the flow stress curve of a material?
What are the demands on a temperature measurement setup which allows the evaluation
of simulation results?
Explain the difference between the orthogonal cutting process and the longitudinal cutting
process!
Explain the difference between a plastic and an elastic-plastic flow stress curve!
WZL/Fraunhofer IPT
Seite 92