Abstract: Present study is aimed on the cutting process of circular
cross-section rods where the fracture is used to separate one rod
into two pieces. Incorporating the phenomenological ductile fracture
model into the explicit formulation of finite element method, the
process can be analyzed without the necessity of realizing too many
real experiments which could be expensive in case of repetitive
testing in different conditions. In the present paper, the steel AISI
1045 was examined and the tensile tests of smooth and notched
cylindrical bars were conducted together with biaxial testing of the
notched tube specimens to calibrate material constants of selected
phenomenological ductile fracture models. These were implemented
into the Abaqus/Explicit through user subroutine VUMAT and used
for cutting process simulation. As the calibration process is based
on variables which cannot be obtained directly from experiments,
numerical simulations of fracture tests are inevitable part of the
calibration. Finally, experiments regarding the cutting process were
carried out and predictive capability of selected fracture models is
discussed. Concluding remarks then make the summary of gained
experience both with the calibration and application of particular
ductile fracture criteria.
Abstract: Chatter vibration has been a troublesome problem
for a machine tool toward the high precision and high speed machining.
Essentially, the machining performance is determined by the dynamic
characteristics of the machine tool structure and dynamics of cutting
process, which can further be identified in terms of the stability lobe
diagram. Therefore, realization on the machine tool dynamic behavior
can help to enhance the cutting stability. To assess the dynamic
characteristics and machining stability of a vertical milling system
under the influence of a linear guide, this study developed a finite
element model integrated the modeling of linear components with the
implementation of contact stiffness at the rolling interface. Both the
finite element simulations and experimental measurements reveal that
the linear guide with different preload greatly affects the vibration
behavior and milling stability of the vertical column spindle head
system, which also clearly indicate that the predictions of the
machining stability agree well with the cutting tests. It is believed that
the proposed model can be successfully applied to evaluate the
dynamics performance of machine tool systems of various
configurations.