Prediction of Cutting Force and Chip Formation from the True Stress–Strain Relation Using an Explicit FEM for Polymer Machining
In the present work, an explicit finite element (FE) model was developed for predicting cutting forces and chip morphologies of polymers from the true stress–strain curve. A dual fracture process was used to simulate the cutting chip formation, incorporating both the shear damage failure criterion a...
| Main Authors: | , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
MDPI AG
2022-01-01
|
| Series: | Polymers |
| Subjects: | |
| Online Access: | https://www.mdpi.com/2073-4360/14/1/189 |
| _version_ | 1797497842060754944 |
|---|---|
| author | Bin Yang Hongjian Wang Kunkun Fu Chonglei Wang |
| author_facet | Bin Yang Hongjian Wang Kunkun Fu Chonglei Wang |
| author_sort | Bin Yang |
| collection | DOAJ |
| description | In the present work, an explicit finite element (FE) model was developed for predicting cutting forces and chip morphologies of polymers from the true stress–strain curve. A dual fracture process was used to simulate the cutting chip formation, incorporating both the shear damage failure criterion and the yield failure criterion, and considering the strain rate effect based on the Johnson–Cook formulation. The frictional behaviour between the cutting tool and specimen was defined by Coulomb’s law. Further, the estimated cutting forces and chip thicknesses at different nominal cutting depths were utilized to determine the fracture toughness of the polymer, using an existing mechanics method. It was found that the fracture toughness, cutting forces, and chip morphologies predicted by the FE model were consistent with the experimental results, which proved that the present FE model could effectively reflect the cutting process. In addition, a parametrical analysis was performed to investigate the effects of cutting depth, rake angle, and friction coefficient on the cutting force and chip formation, which found that, among these parameters, the friction coefficient had the greatest effect on cutting force. |
| first_indexed | 2024-03-10T03:25:00Z |
| format | Article |
| id | doaj.art-541b92ceac42416b83344e512dc2cbfd |
| institution | Directory Open Access Journal |
| issn | 2073-4360 |
| language | English |
| last_indexed | 2024-03-10T03:25:00Z |
| publishDate | 2022-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Polymers |
| spelling | doaj.art-541b92ceac42416b83344e512dc2cbfd2023-11-23T12:11:11ZengMDPI AGPolymers2073-43602022-01-0114118910.3390/polym14010189Prediction of Cutting Force and Chip Formation from the True Stress–Strain Relation Using an Explicit FEM for Polymer MachiningBin Yang0Hongjian Wang1Kunkun Fu2Chonglei Wang3School of Aerospace Engineering and Applied Mechanics, Tongji University, Shanghai 200092, ChinaSchool of Aerospace, Mechanical and Mechatronic Engineering, The University of Sydney, Sydney 2006, AustraliaSchool of Aerospace Engineering and Applied Mechanics, Tongji University, Shanghai 200092, ChinaCollege of Shipbuilding Engineering, Harbin Engineering University, Harbin 150001, ChinaIn the present work, an explicit finite element (FE) model was developed for predicting cutting forces and chip morphologies of polymers from the true stress–strain curve. A dual fracture process was used to simulate the cutting chip formation, incorporating both the shear damage failure criterion and the yield failure criterion, and considering the strain rate effect based on the Johnson–Cook formulation. The frictional behaviour between the cutting tool and specimen was defined by Coulomb’s law. Further, the estimated cutting forces and chip thicknesses at different nominal cutting depths were utilized to determine the fracture toughness of the polymer, using an existing mechanics method. It was found that the fracture toughness, cutting forces, and chip morphologies predicted by the FE model were consistent with the experimental results, which proved that the present FE model could effectively reflect the cutting process. In addition, a parametrical analysis was performed to investigate the effects of cutting depth, rake angle, and friction coefficient on the cutting force and chip formation, which found that, among these parameters, the friction coefficient had the greatest effect on cutting force.https://www.mdpi.com/2073-4360/14/1/189cutting forcechip formationorthogonal cuttingexplicit FEM |
| spellingShingle | Bin Yang Hongjian Wang Kunkun Fu Chonglei Wang Prediction of Cutting Force and Chip Formation from the True Stress–Strain Relation Using an Explicit FEM for Polymer Machining Polymers cutting force chip formation orthogonal cutting explicit FEM |
| title | Prediction of Cutting Force and Chip Formation from the True Stress–Strain Relation Using an Explicit FEM for Polymer Machining |
| title_full | Prediction of Cutting Force and Chip Formation from the True Stress–Strain Relation Using an Explicit FEM for Polymer Machining |
| title_fullStr | Prediction of Cutting Force and Chip Formation from the True Stress–Strain Relation Using an Explicit FEM for Polymer Machining |
| title_full_unstemmed | Prediction of Cutting Force and Chip Formation from the True Stress–Strain Relation Using an Explicit FEM for Polymer Machining |
| title_short | Prediction of Cutting Force and Chip Formation from the True Stress–Strain Relation Using an Explicit FEM for Polymer Machining |
| title_sort | prediction of cutting force and chip formation from the true stress strain relation using an explicit fem for polymer machining |
| topic | cutting force chip formation orthogonal cutting explicit FEM |
| url | https://www.mdpi.com/2073-4360/14/1/189 |
| work_keys_str_mv | AT binyang predictionofcuttingforceandchipformationfromthetruestressstrainrelationusinganexplicitfemforpolymermachining AT hongjianwang predictionofcuttingforceandchipformationfromthetruestressstrainrelationusinganexplicitfemforpolymermachining AT kunkunfu predictionofcuttingforceandchipformationfromthetruestressstrainrelationusinganexplicitfemforpolymermachining AT chongleiwang predictionofcuttingforceandchipformationfromthetruestressstrainrelationusinganexplicitfemforpolymermachining |