Fe Simulation of Cutting Processes

Finite element simulation of cutting
processes
Simulation Techniques in Manufacturing Technology
Lecture 8
Laboratory for Machine Tools and Production Engineering
Chair of Manufacturing Technology
Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Dr. h.c. F. Klocke

WZL/Fraunhofer IPT
Outline
1
Introduction
Requirements of the FE cutting simulation
CAD modelling for the FE cutting simulation
Constitutive material laws for the FE cutting simulation
Damage models for the FE cutting simulation and multiphase simulation
Friction and wear models for the FE cutting simulation
Criteria for the evaluation of FE software
Applications of the FE cutting simulation at the WZL
Summary and Outlook
WZL/Fraunhofer IPT
Seite 2
Influencing factors on the cutting process

Bild
eines
Prozesses
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
Cutting process in comparison to other processes

Process
Strain
Strain rate / s-1
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
Extreme conditions in the cutting process

Source: Jaspers
WZL/Fraunhofer IPT
Seite 4
Outline
1
Introduction
Summary and Outlook
WZL/Fraunhofer IPT
Seite 5
Requirements to the FE cutting simulation

Reproduction of the macro/ micro geometry of the tools and kinematic of the cutting
process
Modelling of the thermo mechanical material behavior for the entire temperature and
strain rate range

Implementation of damage approaches, texture microstructure and phase transformation
Simulation of chip form (remeshing routine, material separation, etc.)
Consideration of friction, wear and coating
Modelling of heat generation and transfer (conduction, convection, radiation)
Consideration of the influence of cooling lubricant
Utilization of the Lagrangian solving method (instationary cutting processes)
Generation of a finely structured FE mesh and adaptive remeshing (very high element
deformation because of higher gradients of deformation, temperature and tension)

Appropriate computation time (explicit time integration, parallelization, etc.)
WZL/Fraunhofer IPT
Seite 6
Cutting simulation: Input- und output parameters

Chip formation
Temperature
Tension
Deformation
Rate of deformation
Chip type
Chip flow
Chip crack
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
Summary and Outlook
WZL/Fraunhofer IPT
Seite 8
Macro- und micro tool geometry
major
Hauptschneide
cutting edge
Querschneide
chisel edge
flank
Freiflface
che
Construction dimensions DIN 6539

Type:
N
Diameter:
d = 1 mm
Drill-point angle: s = 118
WZL/Fraunhofer IPT
Major clearance angle:

Twist angle:
Cutting material:
Grain size:
a = 10
d = 35
HW-K20
DK = 0.5 0.7 m
Seite 9
Definition of element type
WZL/Fraunhofer IPT
Seite 10
Creation of tool models close to reality

Drilling tool
Determination of the tool geometry

Real tool
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
Thermo-mechanical behavior of material
Bi u i
WZL/Fraunhofer IPT
Seite 13
Thermo-mechanical behavior of material
s s ( , , T )
Strain Hardening
Strain Rate Hardening
450
Thermal Softening
450
450
-3 -1
d/dt=10 s & T=20C
=0.1 & T=20C
=0.1 & d/dt=1s
s , MPa
400
400
300
350
150
-1
350
300
250
AA6063-T6
200
0.1
Source: Diss- Abouridouane
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
Constitutive material modelling for the FE cutting simulation

m
T Tr
s (A B ) (1 C ln( / 0 )) (1
)
Tm Tr Thermal softening
Empirical models: e.g. Johnson-Cook-Modell
Strain hardening
Strain rate sensitivity
Micro mechanical models: e.g. enhanced Macherauch-Vhringer-Kocks-model

1/ q 1/ p
kT
0
s sa s 1
ln
G 0
*
0
Athermal processes
Damping process
Thermal activated processes

Semi-empirical models: e.g. Zerilli-Armstrong-model for bcc-materials
= G + C1 exp -C2T + C3T ln() + C4 n + C5 L-1/2
Initial density
of dislocations
Source: Diss-Abouridouane
WZL/Fraunhofer IPT
Influence of temperature
and strain rate
Dislocation jam
Influence of grain size

Seite 15
Determination of High speed flow curves

Split-Hopkinson-Pressure-Bar
Projectile
Projektil
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:
500 s-1 10000 s-1
Temperature range:
93 K 1273 K
Projectile speed:
2,5 m/s 50 m/s
Projectile mass:
m = 3,15 kg
Seite 16
Material law for high strain rate deformation
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
True plastic strain, -
Source: Diss-Brodmann
WZL/Fraunhofer IPT
Seite 17
Outline
1
Introduction
Summary and Outlook
WZL/Fraunhofer IPT
Seite 18
Failure mechanisms
Loading type
Tensile stress
Shear stress
TiAl6V4
20 m
Shear lokalisation model

(Imperfections theory)
20 m
Pore growth model

(Hancock-Mackenzie)
WZL/Fraunhofer IPT
Seite 19
Damage modelling for the FE cutting simulation (ductile fracture)

s
Macro mechanical failure models

Equivalent stress/ strain model:
Gosh-Model:
Ayada-Model:
dD
D = v,f / D = v,f
DGosh = (1+2/1) 12
= (m/v) dv
s0
E
Micro mechanical failure models (Pore growth models)

Hancock-Mackenzie-Modell
3 m
f = n + exp
2 v
Gurson-Tveergard-Needleman-Model
Johnson-Cook-Model
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
Failure limit at tensile stress (r: Notch radius)

lokale
plastische
Bruch-Vergleichsdehnung
Local
plastic
failure-equivalent
stress f f
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
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
Criteria for chip formation

Physical separation criterion
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
Separation while exceeding

Separation when
the cutting edge falls below a

critical distance dcr to the
next workpiece node
WZL/Fraunhofer IPT
an defined, maximum
equivalent stress or at
predefined maximum
tensions
Separation through
continuous remeshing for

ductile material behavior
Seite 22
Chip separation - without chip separation criterion by remeshing

Old Mesh
New Mesh
Elements are highly distorted
Remeshing leads to better mesh
a)
Span
Chip
Werkzeug
Tool
b)
New Mesh
WZL/Fraunhofer IPT
Seite 23
Microstructure-based 3D modeling for micro cutting AISI 1045

Concept of the Representative Volume Element (RVE)
Capture of all significant microstructural
inhomogeneities
Representativeness check of the RVE

1200
Tension stress
Tension
Compression
Microstructure
Macrostructure
RVE
True stress MPa
900
Two-phase 3D FE model
Cross section
(0.1 x 0.1 x 0.1 mm)
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
True plastic strain , , -
Pearlite
WZL/Fraunhofer IPT
Ferrite
Seite 24
Microstructure-based 3D FE model: Validation
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
Two-phase FE model for

micro drilling in
ferritic-pearlitic carbon steel C45N
Microstructure
0
0
d = 1 mm, vc = 35 m/min, f = 12 m
Drill
Workpiece
Holes
Workpiece
WZL/Fraunhofer IPT
Chip form
Seite 25
Influence on the formation of residual stresses
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
stresses has not been done

Source: Preckel
WZL/Fraunhofer IPT
Seite 26
Input parameters for thermo-mechanical-metallurgic simulation

(residual stresses)
Microstructure, initial state of texture
Time dependent thermo-mechanical state of stress
Mathematical approach for the diffusion controlled transformation kinetics:
Advanced Johnson-Mehl-Avrami-Kolmogrow-model, 1940

Mathematical approach for the phase transformation without diffusion
Koistenen-Marburger-relation, 1959
TTT/TTA-diagram for not isotherm conditions (high strain rate)
Thermal material properties, depending on temperature (cp, l r )
Mechanical material properties, depending on temperature (E, u a ...)

Elasto-viscoplastic material law
Consideration of grain orientation, texture, micro damages, inclusions, etc.
Description of the damage behavior on high strain rates

Tool wear model
WZL/Fraunhofer IPT
Seite 27
Outline
1
Introduction
Applications of the FE-cutting-simulation at the WZL
Summary and Outlook
WZL/Fraunhofer IPT
Seite 28
Friction model for FE cutting simulation

Thermal load at the workpiece and tool contact zone
Structure in the workpiece
Shear edge
vc
Distribution of temperature in the contact

zone
(according to Kronenberg)
Workpiece
300
Structure in the chip

5
1
3
4
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

Deformation at the workpiece and tool contact zone
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 flank face
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

Mechanical stress at the workpiece and tool contact zone
Shear edge
vc
Structure
in the chip
5
3
Cutting edge
Tool
Primary shear zone
Secondary shear zone at the flank face
WZL/Fraunhofer IPT
Shear stress:
Tool flank
Cutting surface
1
2
3
4
5
Normal stress:
Contact zone
Tool
According to Oxley and Hatton
Seite 31

R
Coulomb friction model :
Coulomb friction
R s N
Shear friction
Shear friction model:
reality
R m k
with
kf
3
Continuous passover from dynamic friction
Dynamic friction
Static friction
sN
Usiu
Shaw /
Wanheim and Bay
sN
WZL/Fraunhofer IPT
Z.B.: Usui-model
= 1 exp( )
Orowan / zel
reality
(Coulomb) to static friction (shear):
shear stress from friction
sN
normal stress
yield stress in shear according to Mises
kf
yield stress according to Mises
, m
friction coefficients
Seite 32
Wear model for FE cutting simulation

Different types of wear at the cutting blade and wear mechanisms
Cuttingsurface
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
Wear model for FE cutting simulation

Tool wear modelling
Differential
wear models
Tool life equations

Tool life acc. to Taylor:
Tool life acc. to Hasting:
T v ck Cv
T = tool life
u = temperature
k, A, B = constant
Cv = T fr vc = 1 m/min
Empirical tool wear

models
Physical tool wear

models
Adhesion
Abrasion + Diffusion
Model acc. to Archard: Model acc. to Usui:
Model acc. to Takeyama:
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
Object boundary conditions

Boundary Conditions
Object Conditions
Inter Object Conditions
Environment Object Conditions
Tool
Workpiece
2D FEM Cutting Model
WZL/Fraunhofer IPT
Seite 35

Boundary Conditions
Object Conditions
Friction
Heat Transfer
Tool
Movement
=
Object 1
Workpiece = Object 2
WZL/Fraunhofer IPT
Seite 36
Boundary conditions
Boundary Conditions
Self Contact (Chip vs. Workpiece Surface)
Object Conditions
Friction
Heat Transfer
FN
Movement
FR
FR: Friction Force

Workpiece = Object 2
FN: Normal Force

WZL/Fraunhofer IPT
Seite 37

Boundary Conditions
The workpiece is moving in

x-direction with the prescribed
velocity vc. It is fixed in y-direction
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

Boundary Conditions
Tool
Object Conditions
Heat Transfer
Friction
Heat Transfer
Movement
Workpiece
WZL/Fraunhofer IPT
Seite 39

Boundary Conditions
Object Conditions
Friction
Heat Transfer
Tool
FN
FN
Heat Transfer
FR
FN
WZL/Fraunhofer IPT
Seite 40

Boundary Conditions
Object Conditions
Heat Transfer
Tool
Heat Convection
Heat Emissivity
Heat Radiation
Heat Convection
Heat exchange with

environment
WZL/Fraunhofer IPT
Seite 41
Outline
1
Introduction
Applications of the FE-cutting-simulation at the WZL
Summary and Outlook
WZL/Fraunhofer IPT
Seite 42
FEM software solution for FEM simulation of the cutting process
MSC.Marc
WZL/Fraunhofer IPT
Seite 43

Programm
ABAQUS
ANSYS/ LS-DYNA
AdvantEdge
DEFORM
COMSOL
Criteria
Creation of geometries
Creation of geometries
and import of CAD data
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
No, has to be defined
Yes, expandable
Yes, wide
Yes, new catalogue

importable
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
Usage at the WZL
Eigenfrequency analysis,
elast. Tool behavior,
elasto-plastic component
behavior
no
no
Cutting simulation
Thermo-elastic
deformation
Source: SIMULIA, ANSYS, LSTC, TWS, SFTC, COMSOL

WZL/Fraunhofer IPT
Seite 44
Outline
1
Introduction
Summary and Outlook
WZL/Fraunhofer IPT
Seite 45
Applications of the FE cutting simulation at WZL

2D, e.g. Planing
Drilling
Milling
Turning
Research focus at the WZL:

Process optimization
Material modelling
WZL/Fraunhofer IPT
Seite 46
Simulation of the high speed cutting process
Cutting speed: vc = 3000 m/min

Feed:
f = 0.25 mm
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
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WZL/Fraunhofer IPT
Seite 53
Comparison of different thermal properties of the tools

Orthogonal turning 2D (vc = 300 m/min, f = 0,1 mm, C45E)
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
Temperature distribution in dependency of the coating and

its thickness
TiN
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
FE-Based calibration process for tool wear model

Modeling
Verschleimarkenbreite ber die Schnittzeit

16MnCr5 (einsatzgehrtet), Stegbreite = 1 mm, cBN bestckte Einstechplatte der Sorte N151.2-600-50E-G
Schnittgeschwindigkeit vc = 150, 200, 300 m/min und Vorschub f = 0,06 mm
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]
2D FE model for tool wear simulation
WZL/Fraunhofer IPT
Tool life
Seite 57
Phase 3: Methodology for moving the nodes at the rake face

Tool
node
square element
Tool
Workpiece
vc
Rake
Chip
vc
WZL/Fraunhofer IPT
Seite 58
Phase 3: Methodology for moving the nodes at the flank face
node
square element
5 m
nB
nA
A
Workpiece
WZL/Fraunhofer IPT
Tool
nC
C
nD
Flank
D
nA = nB = nC = nD
Seite 59
Verification of the tool wear simulation for the flank wear

vc = 150 m/min, f = 0.06 mm, ap = 1 mm, dry
eff = -26
Tool
[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
Setup of a 3D FE model - specification of the tool holder

Tool holder:
RotZ=6
Kennametal
ID: PCLNL252M12 F4 NG27
Rake angle 0 = -6
Relief angle a0 = 6
Tool inclination angle ls = -6
Rotx=-6
WZL/Fraunhofer IPT
Tool cutting edge angle r = 95
Seite 62
Setup of a 3D FE model - Tool position
tool
ap
r
WZL/Fraunhofer IPT
tool
=r
workpiece
workpiece
Seite 63
Setup of a 3D FE model - Mesh of the workpiece
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
3D FE model - Post processing

Temperature (C)
For better visualization
the tool is hidden
WZL/Fraunhofer IPT
Seite 66

Temperature (C)
the tool is hidden
WZL/Fraunhofer IPT
Seite 67

Strain distribution
Strain

the tool is cut
WZL/Fraunhofer IPT
Seite 68
Strain Rate
Strain Rate
distribution
the tool is cut
WZL/Fraunhofer IPT
Seite 69
Models of cutting inserts
Roughing geometry
CNMG120408RN
WZL/Fraunhofer IPT
Finishing geometry
CNMG120408FN
Seite 70
Simulation of the chip flow

Chip breaker FN
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
Simulation of the chip flow

Chip breaker FN
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
Comparison of simulation and real chip flow

CNMG120408
Chip breaker NF
HC-P15
r = 95
n = -6
ls = -6
C45E+N
ap = 1,9 mm
f = 0,25 mm
vc = 200 m/min
dry
vf
WZL/Fraunhofer IPT
vc
Seite 73
Drilling: Modelling of size effects

Task:
Development of a consistent 3D computation model based on the FE method
for scaling the drilling process in consideration of size effects
n
drill
f Bohrwerkzeug
Friction
Reibung
Reibung
Friction
Workpiece
Werkstck
Plastic
Plastische
Verformung
deformation
WZL/Fraunhofer IPT
Stofftrennungof material
Separation
Seite 74
Previous results: 3D FE computation model for d = 1 10 mm

Material modeling
s s(, , T)
Measuring the drill geometry

Tool
FE boundary conditions
FEM-Model
Strain hardening
Cutting parameters
Plasticity
Tool: rigid / elastic
Damping mechanism
Friction law
Relaxation
Heat transfer
Dynamic strain ageing
Element size
Temperature influence
Number of elements
Loss of cohesion
Remeshing strategy
Failure mechanism
Degree of freedom
WZL/Fraunhofer IPT
Seite 75
FE-Simulation of the drilling process with d = 1 mm (DEFORM 3D)

Machining conditions
Workpiece material:
Tool material:
Cutting speed:
Feed:
Feed velocity:
Cooling lubricant:
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
Verification of the chip formation

Chip formation in the simulation
Experimental chip formation
Workpiece material:
C45E+N
Cutting speed: vc = 35 m/min
Cutting tool material:
HW K20
Feed:
WZL/Fraunhofer IPT
f = 0.012 mm
Seite 77
Model validation: Scaling effect of the chisel edge length

6
Verhltnis (dQ / d) [%]
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
Model validation: Temperature at the main cutting edge (center)
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
Modelling of the face milling process

Materials and cutting parameters:
Work material:
Quenched and tempered AISI 1045 (normalized)
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
Feed per tooth:
fZ = 0.125 mm
Depth of cut:
ap = 0.8 mm
Tool leading angle:
r = 90
Tool inclination angle:
= -5
No. of rev.:
n = 2250 min-1
WZL/Fraunhofer IPT
Tool
r
ap
Workpiece
Seite 80

Axial and radial rake angle:
Axial rake angle
axial = 9
Radial rake angle
radial = 5
axial
WZL/Fraunhofer IPT
Seite 81

Depth of cut ap
r
Feed f
Workpiece geometry
tool
= r Workpiece
r Tool
View
ap
r Workpiece
WZL/Fraunhofer IPT
Seite 82
Finding the best workpiece geometry

1. Simplified
workpiece
geometry
2. Simplified workpiece geometry

1
3. Simplified workpiece geometry
WZL/Fraunhofer IPT
Seite 83
Simulation results for the 1. simplified workpiece model

Rough elements within the
work piece
Simulation of chip formation
not accurate enough
back
WZL/Fraunhofer IPT
Seite 84
Simulation results for the 3. simplified workpiece model

Final workpiece geometry
Left
WZL/Fraunhofer IPT
Right
Seite 85
Results for the face milling operation

Chip formation for the left
side of the work piece:
at the beginning very thin
chips are produced

chip curling starts for higher
undeformed chip thickness
WZL/Fraunhofer IPT
Seite 86
Verification of the FE model

Experiment
Simulation
Full agreement
WZL/Fraunhofer IPT
Seite 87
FE based sensitivity analysis

Varied input
parameters:
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
Summary and Outlook
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
conventional empirical or analytical approaches
FEM is a promising method for the holistic simulation of machining

High flexibility
Implementation of various models that describe the aspects of machining
Complete reproduction of the machining process
The FE cutting Simulation gives good results under the following boundary conditions:
Realistic reproduction of the tools macro/ micro geometry
Adequate modeling of the thermo mechanical material behavior
Exact capturing of the boundary conditions (friction, heat transfer, wear , cooling lubricant, damage,
micro structure, etc.)
WZL/Fraunhofer IPT
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

Fe Simulation of Cutting Processes

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Fe Simulation of Cutting Processes

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Finite element simulation of cutting

Prof. Dr.-Ing. Dr.-Ing. E.h. Dr. h.c. Dr. h.c. F. Klocke

Requirements of the FE cutting simulation

CAD modelling for the FE cutting simulation

Constitutive material laws for the FE cutting simulation

Damage models for the FE cutting simulation and multiphase simulation

Friction and wear models for the FE cutting simulation

Criteria for the evaluation of FE software

Applications of the FE cutting simulation at the WZL

Summary and Outlook

Influencing factors on the cutting process

Cutting process in comparison to other processes

Strain rate / s-1

Extreme conditions in the cutting process

Requirements of the FE cutting simulation

CAD modelling for the FE cutting simulation

Constitutive material laws for the FE cutting simulation

Damage models for the FE cutting simulation and multiphase simulation

Friction and wear models for the FE cutting simulation

Criteria for the evaluation of FE software

Applications of the FE cutting simulation at the WZL

Summary and Outlook

Requirements to the FE cutting simulation

strain rate range

deformation because of higher gradients of deformation, temperature and tension)

Cutting simulation: Input- und output parameters

Requirements of the FE cutting simulation

CAD modelling for the FE cutting simulation

Constitutive material laws for the FE cutting simulation

Damage models for the FE cutting simulation and multiphase simulation

Friction and wear models for the FE cutting simulation

Criteria for the evaluation of FE software

Applications of the FE cutting simulation at the WZL

Summary and Outlook

Macro- und micro tool geometry

Construction dimensions DIN 6539

Major clearance angle:

Definition of element type

Creation of tool models close to reality

Determination of the tool geometry

Requirements of the FE cutting simulation

CAD modelling for the FE cutting simulation

Constitutive material laws for the FE cutting simulation

Damage models for the FE cutting simulation and multiphase simulation

Friction and wear models for the FE cutting simulation

Criteria for the evaluation of FE software

Applications of the FE cutting simulation at the WZL

Thermo-mechanical behavior of material

Thermo-mechanical behavior of material

Strain Rate Hardening

d/dt=10 s & T=20C

=0.1 & T=20C

=0.1 & d/dt=1s

Source: Diss- Abouridouane

Constitutive material modelling for the FE cutting simulation

Empirical models: e.g. Johnson-Cook-Modell

Strain rate sensitivity

Micro mechanical models: e.g. enhanced Macherauch-Vhringer-Kocks-model

Thermal activated processes

= G + C1 exp -C2T + C3T ln() + C4 n + C5 L-1/2

Influence of grain size

Determination of High speed flow curves

500 s-1 10000 s-1

2,5 m/s 50 m/s