Considering multiple process observables to determine material model parameters for FE-cutting simulations

The International Journal of Advanced Manufacturing Technology, vol. 113, pp. 3419–3431

Abstract

Abstract Analyzing the chip formation process by means of the finite element method (FEM) is an established procedure to understand the cutting process. For a realistic simulation, different input models are required, among which the material model is crucial. To determine the underlying material model parameters, inverse methods have found an increasing acceptance within the last decade. The calculated model parameters exhibit good validity within the domain of investigation, but suffer from their non-uniqueness. To overcome the drawback of the non-uniqueness, the literature suggests either to enlarge the domain of experimental investigations or to use more process observables as validation parameters. This paper presents a novel approach merging both suggestions: a fully automatized procedure in conjunction with the use of multiple process observables is utilized to investigate the non-uniqueness of material model parameters for the domain of cutting simulations. The underlying approach is two-fold: Firstly, the accuracy of the evaluated process observables from FE simulations is enhanced by establishing an automatized routine. Secondly, the number of process observables that are considered in the inverse approach is increased. For this purpose, the cutting force, cutting normal force, chip temperature, chip thickness, and chip radius are taken into account. It was shown that multiple parameter sets of the material model can result in almost identical simulation results in terms of the simulated process observables and the local material loads.

Authors 2

1. Marvin Hardt corresponding Aachen Laboratory for Machine Tools and Production Engineering (WZL)

   RWTH Aachen University

   Affiliation as printed

   Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University, Campus-Boulevard 30, 52074, Aachen, Germany

2. Thomas Bergs Aachen Laboratory for Machine Tools and Production Engineering (WZL) Fraunhofer Institute for Production Technology IPT

   RWTH Aachen University · Fraunhofer Institute for Production Technology IPT

   Affiliation as printed

   Fraunhofer Institute for Production Technology IPT, Steinbachstr. 17, 52074, Aachen, Germany

   Laboratory for Machine Tools and Production Engineering (WZL) of RWTH Aachen University, Campus-Boulevard 30, 52074, Aachen, Germany