Numerical analysis of crack propagation during the burr formation process of metals
Source: International Journal of Machining and Machinability of Materials, Volume 6, Numbers 1-2, 9 July 2009 , pp. 54-68(15)
Publisher: Inderscience Publishers
Abstract:Because of increased productivity demands in manufacturing the attention in burr problems is steadily turned to the avoidance of burr. With this initial point this paper contributes to the analysis and simulation of burr separation at workpiece material AISI 1045 steel (C45E). At first 12 known crack initiation criteria are investigated whether they are suitable to simulate crack initiation during burr formation. It is shown that eight criteria are suitable for the prediction of the crack, whereas the criterion from Cockcroft and Latham has to be pointed out. The implementation of the failure conception of ductile damage from Lemaitre and Sievert indicates the applicability for burr formation simulation with simultaneous simulation of segmented chips. In first calculation, a sliding of the chip could be simulated. At the end the hypothesis of the 'hydrostatic bowl', an area of highly negative pressure in the stage of burr formation, is used to predict the location of crack initiation. The established values correlate better to the experimental tests than these, which are determined by means of fracture criteria.
Document Type: Research article
Affiliations: 1: Institute of Machine Tools and Production Processes, Chemnitz University of Technology, Germany. 2: Department of Materials, University of Oxford, Oxford, UK. 3: Fraunhofer Institute for Machine Tools and Forming Technology, Chemnitz, Germany
Publication date: 2009-07-09
- International Journal of Machining and Machinabilty of Materials is a refereed international publication in the field of machining and machinability of materials. Machining science and technology is an important subject with application in several industries. Parts manufactured by other processes often require further operations before the product is ready for application. Machining is the broad term used to describe removal of material from a workpiece, and covers chip formation operations - turning, milling, drilling and grinding, for example. Machining processes can be applied to work metallic and non metallic materials such as polymers, wood, ceramics, composites and special materials. Today, in modern manufacturing engineering, there has been strong renewed interest in high efficiency machining.
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