Please use this identifier to cite or link to this item: http://hdl.handle.net/10603/11707
Title: Investigation of the effect of flow stress models in orthogonal machining using finite element analysis
Researcher: Vijaysekar K S
Guide(s): Pradeep Kumar, M.
Keywords: Flow stress models, orthogonal machining, finite element analysis
Upload Date: 3-Oct-2013
University: Anna University
Completed Date: 
Abstract: Flow stress is a vital input data for the success of finite element (FE) simulations of machining processes. The flow stress is generally measured from Split Hopkinson pressure bar (SHPB) tests and fit to constitutive flow stress models which characterize the flow stress as a function of their strain, strain rate, temperature and microstructure. In the literature, number of flow stress models have been used in FE simulations of the machining process to obtain varied results. The conditions of strain, strain rate and temperature used in SHPB tests for measuring the flow stress are lower than those encountered in machining processes, which induce significant numerical error when applied to machining simulations. In this context, the present research work is focused on analyzing the existing material flow stress models for materials such as AISI 1045 steel, AA 6082 (T6) aluminium alloy and Ti6Al4V titanium alloy and optimizing the material model parameters for the Johnson - Cook (JC) constitutive equation through a combination of Taguchi optimization technique and an inverse FE methodology. The FE results for AISI 1045 steel indicate that the Modified Johnson Cook (MJC) model which does not depend on the yield strength of the material, predicted the cutting force within 3% of the experimental result at the highest feed rate of 0.205 mm/rev. The FE results for AA 6082 (T6) aluminium alloy indicate that the Johnson Cook (JC) model based on SHPB with pre-heating facility simulated the cutting forces within 28% at feed rates of 0.159 mm/rev and 0.205 mm/rev, CTR within 22% at a feed rate of 0.205 mm/rev. The FE analysis of the optimized JC parameters better represented the machining deformation characteristics of AISI 1045 steel, AA 6082 (T6) aluminium alloy and Ti6Al4V titanium alloy than the conventional models suggesting an improvement in the flow stress characterization of the machining process. newline
Pagination: xxxvii, 299
URI: http://hdl.handle.net/10603/11707
Appears in Departments:Faculty of Mechanical Engineering

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02_certificates.pdf886.96 kBAdobe PDFView/Open
03_abstract.pdf19.67 kBAdobe PDFView/Open
04_acknowledement.pdf315.74 kBAdobe PDFView/Open
05_contents.pdf74.09 kBAdobe PDFView/Open
06_chapter 1.pdf163.21 kBAdobe PDFView/Open
07_chapter 2.pdf197.39 kBAdobe PDFView/Open
08_chapter 3.pdf141.76 kBAdobe PDFView/Open
09_chapter 4.pdf123.75 kBAdobe PDFView/Open
10_chapter 5.pdf48.73 kBAdobe PDFView/Open
11_chapter 6.pdf2.28 MBAdobe PDFView/Open
12_chapter 7.pdf27.04 kBAdobe PDFView/Open
13_references.pdf71.53 kBAdobe PDFView/Open
14_publications.pdf17.89 kBAdobe PDFView/Open
15_vitae.pdf13.1 kBAdobe PDFView/Open


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