Some insights on the modelling of chip formation and its morphology during metal cutting operations

Tarek Mabrouki; Cédric Courbon; Yancheng Zhang; Joël Rech; Daniel Nélias; Muhammad Asad; Hédi Hamdi; Salim Belhadi; Ferdinando Salvatore

doi:10.1016/j.crme.2016.02.003

Some insights on the modelling of chip formation and its morphology during metal cutting operations

Tarek Mabrouki ¹ ; Cédric Courbon ²; Yancheng Zhang ³; Joël Rech ²; Daniel Nélias ³; Muhammad Asad ⁴; Hédi Hamdi ²; Salim Belhadi ⁵; Ferdinando Salvatore ²

¹ Université de Tunis El Manar, École nationale d'ingénieurs de Tunis (ENIT), 1002 Tunis, Tunisia
² Université de Lyon, CNRS, École nationale d'ingénieurs de Saint-Étienne, LTDS UMR5513, 42023 Saint-Étienne cedex 2, France
³ Université de Lyon, CNRS, INSA-Lyon, LaMCoS UMR5259, 69621 Villeurbanne cedex, France
⁴ Department of Industrial & Mechanical Engineering, School of Engineering, University of Management & Technology, 54770 Lahore, Pakistan
⁵ Mechanics and Structures Research Laboratory (LMS), 8 May 1945 University of Guelma, P.O. Box 401, 24000, Algeria

Comptes Rendus. Mécanique, Computational simulation of manufacturing processes, Volume 344 (2016) no. 4-5, pp. 335-354.

Abstract

The present paper deals with the mechanisms of chip formation during cutting operations. It deals with some experiments characterising the chip morphologies and microstructure chip investigations under high loadings. In this contribution, mechanisms of chip segmentation are presented. The effect of cutting conditions on cutting forces is treated. Consequently, the chip segmentation phenomenon was correlated to cutting forces evolutions. Also, an investigation on chip strain localisation is carried out. Numerical simulations dealing with chip formation and considering thermomechanical phenomena are also presented. Some numerical results related to chip formation based on the theory of strain gradient plasticity are also discussed. Moreover, the effect of machining system stiffness on chip segmentation is analysed.

Received: 2015-05-10
Accepted: 2015-08-22
Published online: 2016-03-02

DOI: 10.1016/j.crme.2016.02.003

Keywords: Cutting simulation, Plasticity, Damage, Chip formation, Size effect

Author's affiliations:

Tarek Mabrouki ¹; Cédric Courbon ²; Yancheng Zhang ³; Joël Rech ²; Daniel Nélias ³; Muhammad Asad ⁴; Hédi Hamdi ²; Salim Belhadi ⁵; Ferdinando Salvatore ²

¹ Université de Tunis El Manar, École nationale d'ingénieurs de Tunis (ENIT), 1002 Tunis, Tunisia
² Université de Lyon, CNRS, École nationale d'ingénieurs de Saint-Étienne, LTDS UMR5513, 42023 Saint-Étienne cedex 2, France
³ Université de Lyon, CNRS, INSA-Lyon, LaMCoS UMR5259, 69621 Villeurbanne cedex, France
⁴ Department of Industrial & Mechanical Engineering, School of Engineering, University of Management & Technology, 54770 Lahore, Pakistan
⁵ Mechanics and Structures Research Laboratory (LMS), 8 May 1945 University of Guelma, P.O. Box 401, 24000, Algeria

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     title = {Some insights on the modelling of chip formation and its morphology during metal cutting operations},
     journal = {Comptes Rendus. M\'ecanique},
     pages = {335--354},
     publisher = {Elsevier},
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Tarek Mabrouki; Cédric Courbon; Yancheng Zhang; Joël Rech; Daniel Nélias; Muhammad Asad; Hédi Hamdi; Salim Belhadi; Ferdinando Salvatore. Some insights on the modelling of chip formation and its morphology during metal cutting operations. Comptes Rendus. Mécanique, Computational simulation of manufacturing processes, Volume 344 (2016) no. 4-5, pp. 335-354. doi : 10.1016/j.crme.2016.02.003. https://comptes-rendus.academie-sciences.fr/mecanique/articles/10.1016/j.crme.2016.02.003/

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