FLOW STRESS DATA FOR FINITE ELEMENT SIMULATION IN METAL CUTTING: A PROGRESS REPORT ON MADAMS

ABSTRACT

To obtain reliable results from Finite Element (FE) simulation of machining processes, it is necessary to have as input the properties of the workpiece and tool materials as well as the characteristics of the tool/chip interface. These input parameters include physical and thermal data, friction and heat transfer, and most importantly the flow stress of the workpiece material under high strain, strain rate and temperature conditions that exist during the process. This paper presents a brief review of FE simulation of machining processes, a review of the approaches used to determine the flow stress at high deformation rate, and the examples of different constitutive equations used to represent such flow stress data. A material property database (MADAMS) has been developed and provides useful information to conduct simulations of machining processes. The main objectives of the material database are to assist researchers in areas of machining analysis and material modeling and to promote collaboration between various international research groups.

Keywords:

• Flow Stress Data
• Material Database
• Machining
• Metal Cutting
• Finite Element Simulation

ACKNOWLEDGMENTS

The authors would like to gratefully acknowledge the support by two National Science Foundation Grants: grant No. DMI-9821020 (awarded to the Ohio State University) and grant No. DMI-0220924 (awarded to Prof. Jawahir at the University of Kentucky). The authors gratefully acknowledge the contributions of many researchers who provided data for the MADAMS database, especially that of Prof. H.K. Toenshoff at the University of Hannover, Germany who coordinated the DFG project on High Speed Cutting (63).