NUMERICAL PREDICTION EXPERIMENTAL VALIDATION

IMPLEMENTATION
PERSPECTIVES
Thermomechanical approach in finite
transformation
Orthogonal cutting in turning
Down milling
IDENTIFICATION
INTRODUCTION
Study framework and Geometry
Characterization of tool/workpiece interface (thermal fluxes, oxidation, friction, etc.),
Investigation of material inclusion on material machinability,
Study of machined surface integrity (chip segmentation effect on residual stresses distribution and machined surface macro-geometric defects, etc.).
Modeling of micromachining (theory of strain gradient plasticity)
Establishment of numerical modeling: comprehend the physics of material removal with cutting tool
Experimental characterization of machining: control tool wear and its breakage
Experimental/numerical validation
On experimental and numerical approaches for metal cutting
Supervisors: T. Mabrouki (MCF), D. Nlias (Pr), J.-F. Rigal (Pr), PhD students: M. Asad (Bourse, Pakistan), C. Courbon
(Cifre, Ascometal, ENISE, ECL, INSA), F. Girardin (Bourse ministrielle), Y.C. Zhang (CSC, Chine)
University of Lyon, CNRS, INSA-Lyon, LaMCoS, UMR5259, F69621, France.
GEOMETRY
COMPUTATION
RESULTS
Chip morphology
Cutting forces
Residual stresses
Elastic or Rigid body
Rigid or dynamic attachment
Tool
Zorev model
Stick and slip contact
Experimental determination
Interface
Thermal and Mechanical behaviour
Thermal dissipation
Heat partition coefficient
Thermal contact resistance
MONITORING OF SPINDLE SPEED
Material behaviour: Johnson Cook
Experimental identification: Gleeble
Strain gradient strengthening effect for micro-milling
Modified J-C law :
Workpiece Chip
Damage behaviour
Johnson Cook criterion for initiation:
Cumulative law:
Fracture energy in opening / sliding mode:
Linear or exponential damage parameter:
( )
0
. 1 ln . 1
m
n room
melt room
T T
A B C
T T

| | | |
= + +
| |
\ \

0 1 2 3 4 5
0
exp 1 ln 1
room
i
melt room
P T T
D D D D D
T T

| | | | | |
= + + +
| | |
\ \ \

Tool
Interface
Workpiece
Chip
(a) (b)

0
1 exp
u
f
D du
G
| |
= |
|
\

( ) ( )
2
2
, ,
1
f C
I II I II
G K
E
| |
=
|
\
Validation test
Spindle speed Cutting force
Original angular sampling
Use of build-in spindle rotary encoder
Observation of teeth breakages
Titanium alloy, Vc = 140 m/min, fz = 0.3 mm/tth
2 2
18
1
2
G b
JC
JC

| |
|
|
|
|
|
\
= +
Schematic representation of down milling
Orthogonal cutting
Tool
Chip

=
0i
0i

Negative
rake
angle
Positive
rake
angle
46.5 m
Turning case (Titanium alloy) Down milling case (Aluminum alloy)
D
F. Girardin, D. Rmond, J.-F. Rigal. Tool wear detection in milling -An original approach with a non dedicated sensor. Mechanical Systems and Signal Processing, to appear (2010 ).
M. Asad, T. Mabrouki, J.-F. Rigal. Finite-element-based hybrid dynamic cutting model for aluminium alloy milling. Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture (2009).
T. Mabrouki, F. Girardin, M. Asad, J.-F. Rigal. Numerical and experimental study of dry cutting for an aeronautic aluminium alloy (A2024-T351). International Journal of Machine Tools & Manufacture, (2008).
T. Mabrouki, J-F Rigal. A contribution to a qualitative understanding of thermo-mechanical effects during chip formation in hard turning. Journal of material procession and Technology, (2006).
1200
1000
800
600
400
200 150 100 50 0
Experiment
Simulation (with SG)
Simulation (w/o SG)
Uncut chip thickness of Aluminum alloy (m)
C
u
t
t
in
g
s
p
e
c
if
ic
e
n
e
r
g
y
(
M
P
a
)
Chip
Tool
LaMCoS, Universit de Lyon, CNRS, INSA-Lyon UMR5259, 18-20 rue des Sciences - F69621 Villeurbanne Cedex
k
eqy
I
z
m
eq
Mesoscopic level
Orthogonal plane (OP)
a
e
V
f
V
f
Workpiece
N k
r
,C
r
Macroscopic level D
T
Tool
Cutter
x

y
o
k
eqx
C
eqx
C
eqy