NUMERICAL AND EXPERIMENTAL VALIDATION OF CHIP MORPHOLOGY

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International Journal of Advanced Research in Engineering and Technology (IJARET)
Volume 10, Issue 2, March- April 2019, pp. 503-508, Article ID: IJARET_10_02_049
Available online at http://www.iaeme.com/IJARET/issues.asp?JType=IJARET&VType=10&IType=02
ISSN Print: 0976-6480 and ISSN Online: 0976-6499
© IAEME Publication
NUMERICAL AND EXPERIMENTAL
VALIDATION OF CHIP MORPHOLOGY
M. Sivaramakrishnaiah
Mechanical Engineering Sri Venkateswara College of Engineering and Technology,
Chittor-517127, AP, India
P. Nandakumar*
Mechanical Engineering, N.B.K.R. Institute of Science & Technology,
Vidyanagar, S.P.S.R. Nellore Dist-, AP, India
G. Rangajanardhana
Mechanical Engineering, JNTU Anantapuramu, AP, India
*Corresponding Author Email: malayathisiva@gmail.com
ABSTRACT
The extensive research studies are used to divination the behavior of complex
Metal cutting processes. The cutting parameters such as speed, feed and force play
important role on conform chip morphology. The experimental techniques for
investigation the chip morphology is expensive and time consuming. To overcome
these difficulties Finite element modeling and simulation process are used as effective
tool to divination the effect of cutting variables. In the present study FEA simulation
process model is developed to divination the chip morphology and cutting forces in
turning of Al-6061 with WC tool. Johnson cook material models are considered for
visco-elastic material behavior. The obtained simulation process results are compared
with experimental process results.
Keywords: FEM, Chip morphology, DOF, Johnson-Cook material model, WC
Cite this Article: M. Sivaramakrishnaiah, P. Nandakumar, G. Rangajanardhana,
Numerical and Experimental Validation of Chip Morphology, International Journal of
Advanced Research in Engineering and Technology, 10 (2), 2019, pp 503-508.
http://www.iaeme.com/IJARET/issues.asp?JType=IJARET&VType=10&IType=2
1. INTRODUCTION
Metal cutting is most important creating process in processing industry. In Metal cutting, the
procedure of eliminate the excess unwanted material is in appearance of chips through a v-
shaped tool. Chip morphology plays a key role on finish obtained on workpiece machined
surfaces. Hence the study on chip morphology is emphasized. Young [1] indicated the chip
temperatures additionally the tool chip interface temperature using the infrared camera for
cutting tools with different flank wear land values and related flank wear of a cutting tool.

M. Sivaramakrishnaiah, P. Nandakumar, G. Rangajanardhana
Yourong et al. [2] find temperature distribution on the rake and flank side faces of two
ceramic tools during turning operation using the infrared image. Wang et al.[3]used an
infrared imaging system to measure the unsteady temperature passed throughout, within
curled chips during dry machining of cold rolled steel. The surface roughness on machined
surfaces was measured off line on machining of Inconel-600 with carbide tools. Shih [4]
existed a model to analyze the orthogonal Metal cutting with unbreakable chip formation,
using a Eulerian method. He verified that lack of all material properties and friction variables
directly affect the correctness of the finite element simulation process. Shi et al. [5] studied
the cutting with finite element method under plane strain approach. The effect of friction on
thermo mechanical quantities in an Metal cutting process is presented. A friction coefficient
from 0.0 to 0.6 is taken in to consideration and eventually found that general purpose finite
element code ABAQUS used to simulate the Metal cutting process and far chip formation, the
shear angle of initial primary shear zone, increasing in temperature and required force, depend
strongly on the coefficient of friction and on the rake angle. Fang and Jawahir [6] divination
three important machining variables, i.e. the cutting force ratio, chip size, and chip back-flow
angle, on the basis of universal slip-line model, a maximum value principle in order to find
the stresses in the plastic zone in restricted machining. Fang [7] suggest a slip-line model in
favor of the tool–chip contact zone on the tool secondary rake face. Spiral chip in machining
was also taken in to account. Fang [8] analyzed the forces, chip thickness, and tool–chip
contact length in machining with a rake-angled tool and reveal that double-rake-angled tool
increases the thrust forces in comparison with single rake angled tool. Found that tool–chip
contact friction on the tool secondary zone rake face plays an role in machining than the tool–
chip friction on the tool primary zone rake face. Shet and Deng [9] funish a finite element
method to simulate and to analyze the orthogonal Metal cutting process under plane strain
conditions, with main on the residual stress and strain fields in the finished work piece. The
main target of this work is to divination the forces and chip morphology, in the chip formation
region using the method of FEM in turning process. Further the obtained fem simulation
process results are compared with experimental process results of forces and chip morphology
measured by three dimensional Dynamometer and Tool makers microscope.
2. NUMERICAL SIMULATION PROCESS
For accurate simulation process of Metal cutting by finite element procedure, a better
perception of the material removal process in Metal cutting is first necessary. Metal cutting is
a highly nonlinear and combined thermo-mechanical process. Coupling is initiate because of
confine heating, temperature increases in the work piece and the excess plastic flow in the
shear zone in work piece due to the cutting forces, developed friction through the tool –chip
interface zone. The tool signature and its design plays important role in the dimensional
perfect and surface uprightness of the final product. This complexity is to be translated into
the finite element simulation process. In now a days, finite element method emerged as a tool
for the analysis process of Metal cutting because it has following.
3.1. Tool and Workpiece Modeling
From the practical approach, it is show that the tool model has a great impact on the surface
model of the machined work piece. Hence it is important to model the design of tool model.
In the present numerical analysis process, the tool of Tungsten carbide (WC) material is
selected with 8º rake angle, 3º clearance angle and 0.8 mm nose radius. Tool geometry and
work dimensions are as shown in Fig 1.

Numerical and Experimental Validation of Chip Morphology
Figure 1 2D Modeling of Tool and workpiece Figure 2 Mesh generation
Work piece material properties (Al-6061) are shown in Table.1. During cutting process
the plastic behavior of material is transient due to localized heating, temp distribution and the
friction. To study the plastic behavior of Al-6061, the Johnson cook material constitutive
model is used. Johnson cook material constants used are presented in the Table 2. As shown
in Fig. 1, work piece dimensions of 10mm x 3mm, and width of tool about 1mm is
considered. ABAQUS as plane stress/strain thickness.
Table 1 Thermo mechanical Properties of the Work piece and Tool Material.
Properties Young's
modulus
(G Pa)
Density
(kg/m3
)
Poisson Ratio Conductivity
(W/m K)
Specific heat
(J/kg K)
Al-6061 (Work
Material)
85 2700 0.29 173 885
WC (Tool
Material)
540 12000 0.22 40 203
Table 2 Material constitutive model (Johnson Cook constants for model) Al-6061
A
MPa
B
MPa
n C m Rake angle º Clearance
angle º
369 684 0.73 0.0083 1.7 8 3
3.2. Meshing of Work and Tool Geometry
To mesh model this behavior CPE4RT element is considered. This element is 4-noded,
bilinear in displacement and temperature, hybrid with constant pressure. It is most reliable for
thermo coupled mechanical application of Metal cutting system. The Johnson–Cook plasticity
model to relate the stress, rate of strain and heat with temperature is the key requirement for a
successful simulation process. Below shows the general equation of this model. The
simulation process used material constitutive model (Johnson cook) depicts the stress as a
function of strain, rate of strain and heat with temperature and it is commonly embedded into
FEM simulation process software(ABAQUS).In this material model, strain hardening
,thermal softening are considered. Where σ is equivalent stress, ε is equivalent plastic strain, T
is temperature of material, Tm is the melting temperature, εo is the strain rate, Tr is the
reference temperature, A, B, m and n are the four coefficients' needed to be included.
( ( [( ) ( ( ) )] (1)
The constants in the equation (1) for Al-6061 are taken from standard experiments.
During simulation process, it is accept that work piece allowed shows only plastic response.
In this simulation process model, surface-to-surface contact is created to define the chip tool
as well as work tool piece interfaces. Fig 2 shows the meshed model with contacts. At this
zone numerical methods become dominant, as in the various outputs and attribute of the Metal
cutting processes such as cutting forces, chip shape, etc. can be divination by using FEM
without doing any experiment.

In this experiments carried out on 2.2KW Kirloskar center lathe with variable speed drive,
the following conditions are explicitly followed for the FE simulation process. Maintain at
constant speeds of 600rpm, 800rpm and 1000 rpm, nose radius of the tool and assumed room
temperature 30°C.Neglected tool wear and consider dry machining for simulation and
experimental.
This Finite element Metal cutting model is developed with three stages: Pre-processing,
Solving, and Post processing. In preprocessing stage, model has been defined with
geometrically suitable boundary conditions and material properties. With meshing it is
submitted to solver to solve all the field variables at the nodes, elements and outputs are
carried to the post processing stage such as sorting, printing and plotting selected results as
shown in Fig.3. Table 3 shows the test cases for which simulation process have been
performed.
Table 3 Experimental & Simulation process Test cases
Parameter Test.1 Test.2 Test.3 Test.4 Test.5 Test.6 Test.7 Test.8 Test.9
Spindle
speed in
rpm
600 800 1000 600 800 1000 600 800 1000
Depth of
cut (DOF)
in mm
0.2 0.2 0.2 0.4 0.4 0.4 0.6 0.6 0.6
Figure 3 Chip formation in different parameters simulation process tests in Al-6061 machining
4. EXPERIMENTAL PROCEDURE
Raw material cut tests are bring out on Al-6061 specimen of 100 mm length,30 mm diameter
is turned by using tungsten carbide tool without coating the lathe used is Kirloskar
Turnmaster-35. All Geared conventional lathe. The tool insert used in the process is THN
SNMG 08. The range of speed up to 1000 rpm can be used on the Machine. The work pieces
are machined previous to the experiments by removing 0.3 mm thick of the top surface in
order to remove any surface defect, present clean surfaces and avoid vibrating behavior
during machining. For each test, sample chips were collected and their thicknesses and chip
width are measured by Tool makers’ Microscope. Cutting forces are measured using Kristlor
Dynamometer. Dynamic behavior was also picked up and displayed by the same instrument.

Numerical and Experimental Validation of Chip Morphology
The chip of thickness, width and cutting forces obtained from the experiments are compared
with the numerical simulation process results.
5. RESULTS AND DISCUSSIONS
The experimental process results are presented in Table 4 for comparisons with ABAQUS
simulation process results. From the experimental process results, chips are found to be
continuous, because of high depth of cut, high cutting speed.Table.4 shows that percentage
difference between FEA and chip width is found in the rage of 1 to 35%,thickness 0 to 9% for
experimental process result validation. The simulation process results and Experimental
process results are pictorially presented in the Fig 5, correspond to the tests 1 to 9
respectively. Tests have been manually taken at 5 dissimilar places to obtain the averaging of
all the instantaneous values of chip width and thickness. Chip burr is neglected. Further
simulation process assume chip width is to be constant which is equal to 1mm. In this
simulation process it represents plane stress/strain thickness. Same method has been complete
for remaining eight cases are indicated in Table 4. Further the study was carried on the effect
of cutting force on chip morphology in both FEM simulation process and experimentation.
The amplitude of resultant forces observed in both simulation process and experimentation
are pictorially presented in the Fig.5.The amplitude of wave form in both experiments and
simulation process show a similar trend. In simulation process, resultant cutting forces differ
by 12% with experimental values. In the test 8 at DOC = 0.6mm, V =800 rpm the magnitude
of cutting force is high in both simulation process and experiment and this may be a causation
for breakage of chip. It is observed that the amplitude was sudden fall and which may have
led for breakage of chip to yield discontinuous chip. While measuring amplitude through
experiments (600 rpm, 0.2mm DOC) the force experienced by the workpiece is an average
amplitude, but on the simulation process it is possible to measure the force component
instantaneously as shown in Fig.5.The ALE simulation process approach presented in this
work with adaptive meshing definitely divination good results for chip morphology. All
above results it is stated that, numerical simulation process software is reliable tool to
divination chip morphology.
Figure 5 Amplitude of force in Experimental and simulation process at 600 rpm, 0.2 DOC

The cutting force affected by friction developed during chip flow The magnitude of cutting
force is gradually increased with increasing speed at constant depth of cut. The magnitude of
cutting force is gradually increased with increasing depth of cut at constant speed. The
magnitude of average cutting forces at higher depth of cut are two times higher than at lower
depth of cut. The test no 8 results displayed discontinuous chip in both experimental and
simulation process. Also the amplitude of cutting force observed a sudden rise and fall
because of discontinuous chip. The amplitude of average force developed during cutting the
work piece is almost same in both experimental method and simulation process method. The
behavior of cutting force both in experimental and simulation process are same. The
considered Johnson cook model parameters proved to be appropriate in divinationing chip
morphology.
REFERENCES
[1] H.-T. Young, Cutting temperature responses to flank wear, 201(1996) 117-120.
[2] L. Yourong, L. Jiajun, Z. Baoliang, D Zhi, Temperature distribution near cutting edge of
ceramic cutting tools measured by thermal video system(TVS), Prog. Natl. Sci. 8 (1) (1998)
44 -50.
[3] L. Wang, K. Saito, I.S. Jawahir, Infrared temperature measurement of curled chip formation in
metal machining, Trans. NAMRI/SMEXXIV (1996) 87-92.
[4] [4] Shih A., Finite Element simulation process of Orthogonal Metal cutting Mechanics, Int.J.
Mech.Tools Manufact., Vol.36, Issue 2,pp.255-273,1996.
[5] Guoqin Shi, Xiaomin Deng, Chandrakanth Shet, ―A finite element study of the effect of
friction in orthogonal Metal cutting‖ Finite Elements in Simulation process and Design 38,pp.
863–883, 2002.
[6] N. Fang a, I.S. Jawahir, ―Analytical divinationions and experimental validation of cutting
force ratio, chip thickness, and chip back-flow angle in restricted contact machining using the
universal slip-line model‖ International Journal of Machine Tools & Manufacture 42,pp. 681–
694, 2002.
[7] N. Fang, ―Machining with tool–chip contact on the tool secondary rake face—Part I: a new
slip-line model ―International Journal of Mechanical Sciences 44,pp. 2337–2354, 2002.
[8] N. Fang, ―Machining with tool–chip contact on the tool secondary rake face—Part II:
simulation process and discussion ―International Journal of Mechanical Sciences 44,pp. 2355–
2368, 2002.
[9] C. Shet, X. Deng, ―Residual stresses and strains in orthogonal Metal cutting‖ International
Journal of Machine Tools& Manufacture 43,pp. 573–587, 2003.

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