A great challenge of metal cutting modeling is the ability of the material constitutive model to describe the mechanical behavior of the work material under the deformation conditions that characterizes this process. In particular, metal cutting generates a large range of state of stresses, as well as strains and strain rates higher than those generated by conventional mechanical tests, including the Split-Hopkinson pressure bar tests. A new hybrid analytical–experimental methodology to identify the material constitutive model coefficients is proposed. This methodology is based on an in situ high-resolution imaging and digital image correlation (DIC) technique, coupled with an analytical model of orthogonal cutting. This methodology is particularly suitable for the identification of the constitutive model coefficients at strains and strain rates higher than those found in mechanical tests. Orthogonal cutting tests of nickel aluminum bronze alloy are performed to obtain the strains and strain rates fields in the cutting zone, using DIC technique. Shear forces derived from stress integrations are matched to the measured ones. Then, the constitutive model coefficients can be determined, which is performed by solving a sequential optimization problem. Verifications are made by comparing the strain, strain rate, and temperature fields of cutting zone from experiments against those obtained by finite element simulations using the identified material constitutive model coefficients as input.
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October 2019
Research-Article
New In Situ Imaging-Based Methodology to Identify the Material Constitutive Model Coefficients in Metal Cutting Process
Xiao-Ming Zhang,
Xiao-Ming Zhang
1
State Key Laboratory of Digital Manufacturing Equipment and Technology,
Wuhan 430074,
e-mails: cheungxm@hust.edu.cn; zhangxm.duyi@gmail.com
Huazhong University of Science and Technology
,Wuhan 430074,
China
e-mails: cheungxm@hust.edu.cn; zhangxm.duyi@gmail.com
1Corresponding author.
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Ke Zhang,
Ke Zhang
State Key Laboratory of Digital Manufacturing Equipment and Technology,
Wuhan 430074,
e-mail: hustzk@hust.edu.cn
Huazhong University of Science and Technology
,Wuhan 430074,
China
e-mail: hustzk@hust.edu.cn
Search for other works by this author on:
Dong Zhang,
Dong Zhang
State Key Laboratory of Digital Manufacturing Equipment and Technology,
Wuhan 430074,
e-mail: zhangdong@hust.edu.cn
Huazhong University of Science and Technology
,Wuhan 430074,
China
e-mail: zhangdong@hust.edu.cn
Search for other works by this author on:
Han Ding
Han Ding
State Key Laboratory of Digital Manufacturing Equipment and Technology,
Wuhan 430074,
e-mail: cheungxm@gmail.com
Huazhong University of Science and Technology
,Wuhan 430074,
China
e-mail: cheungxm@gmail.com
Search for other works by this author on:
Xiao-Ming Zhang
State Key Laboratory of Digital Manufacturing Equipment and Technology,
Wuhan 430074,
e-mails: cheungxm@hust.edu.cn; zhangxm.duyi@gmail.com
Huazhong University of Science and Technology
,Wuhan 430074,
China
e-mails: cheungxm@hust.edu.cn; zhangxm.duyi@gmail.com
Ke Zhang
State Key Laboratory of Digital Manufacturing Equipment and Technology,
Wuhan 430074,
e-mail: hustzk@hust.edu.cn
Huazhong University of Science and Technology
,Wuhan 430074,
China
e-mail: hustzk@hust.edu.cn
Dong Zhang
State Key Laboratory of Digital Manufacturing Equipment and Technology,
Wuhan 430074,
e-mail: zhangdong@hust.edu.cn
Huazhong University of Science and Technology
,Wuhan 430074,
China
e-mail: zhangdong@hust.edu.cn
Jose Outeiro
Han Ding
State Key Laboratory of Digital Manufacturing Equipment and Technology,
Wuhan 430074,
e-mail: cheungxm@gmail.com
Huazhong University of Science and Technology
,Wuhan 430074,
China
e-mail: cheungxm@gmail.com
1Corresponding author.
Manuscript received December 27, 2018; final manuscript received July 1, 2019; published online August 1, 2019. Assoc. Editor: Radu Pavel.
J. Manuf. Sci. Eng. Oct 2019, 141(10): 101007 (11 pages)
Published Online: August 1, 2019
Article history
Received:
December 27, 2018
Revision Received:
July 1, 2019
Accepted:
July 2, 2019
Citation
Zhang, X., Zhang, K., Zhang, D., Outeiro, J., and Ding, H. (August 1, 2019). "New In Situ Imaging-Based Methodology to Identify the Material Constitutive Model Coefficients in Metal Cutting Process." ASME. J. Manuf. Sci. Eng. October 2019; 141(10): 101007. https://doi.org/10.1115/1.4044251
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