Hostname: page-component-586b7cd67f-t7czq Total loading time: 0 Render date: 2024-11-25T23:46:45.067Z Has data issue: false hasContentIssue false
  • English
  • Français

Modified Johnson-Cook Plasticity Model with Damage Evolution: Application to Turning Simulation of 2XXX Aluminium Alloy

Published online by Cambridge University Press:  22 February 2017

H. Ijaz ,
M. Zain-ul-abdein ,
W. Saleem ,
M. Asad  and
T. Mabrouki
H. Ijaz*
Affiliation:
Mechanical Engineering DepartmentUniversity of JeddahJeddah, Saudi Arabia
M. Zain-ul-abdein
Affiliation:
Mechanical Engineering DepartmentUniversity of JeddahJeddah, Saudi Arabia
W. Saleem
Affiliation:
Mechanical Engineering DepartmentUniversity of JeddahJeddah, Saudi Arabia
M. Asad
Affiliation:
Mechanical Engineering DepartmentCollege of EngineeringPrince Mohammad Bin Fahd UniversityAlKhobar, Saudi Arabia
T. Mabrouki
Affiliation:
Mechanical Engineering Department , University of Tunis El Manar, ENIT , Tunis, Tunisia
*
*Corresponding author ([email protected])

Abstract

Core share and HTML view are not available for this content. However, as you have access to this content, a full PDF is available via the ‘Save PDF’ action button.

Mechanical properties of the metals and their alloys are influenced by the material grain size at microscale. In the present study, the Johnson-Cook (JC) material model is modified to incorporate the effect of material's grain size along with the plasticity coupled damage model. 2D finite element (FE) simulations of turning process of an aerospace grade aluminium alloy 2024 (AA2024) were performed with different grain sizes using a commercial FE software, ABAQUS/Explicit. FE simulation results were compared with the published experimental data on turning process of AA2024. The proposed modified JC material model successfully simulated the increase in cutting force as a function of grain size refinement.

Keywords

Finite element analysisModified Johnson-Cook modelGrain sizeTurning process
Type
Research Article
Information
Journal of Mechanics , Volume 33 , Issue 6 , December 2017 , pp. 777 - 788
Copyright
Copyright © The Society of Theoretical and Applied Mechanics 2017 

References

1. Hall, E. O., “The deformation and ageing of mild Steel III—discussion of results,” Proceedings of the Physical Society, Section B, 64, pp. 747–753 (1951).Google Scholar
2. Petch, N. J., “The cleavage strength of polycrystals,” The Journal of the Iron and Steel Institute, 174, pp. 25–28 (1953).Google Scholar
3. Vivekananda, K., Arka, G. N. and Sahoo, S. K., “Finite element analysis and process parameters optimization of ultrasonic vibration assisted turning (UVT),” Procedia Materials Science, 6, pp. 1906–1914 (2014).Google Scholar
4. Stalin John, M. R., Shrivastava, K., Nilanjan, B., Madhukar, P. D. and Vinayagam, B. K., “Finite element method-based machining simulation for analyzing surface roughness during turning operation with HSS and carbide insert tool,” Arabian Journal for Science and Engineering, 38, pp. 1615–1623 (2013).CrossRefGoogle Scholar
5. Agmell, M., Ahadi, A. and Stahl, J. -E., “Identification of plasticity constants from orthogonal cutting and inverse analysis,” Mechanics of Materials, 77, pp. 43–51 (2014).Google Scholar
6. Yin, C. J., Zheng, Q. C. and Hu, Y. H., “Finite element simulation of Titanium alloy turning process,” Applied Mechanics and Materials, 391, pp. 14–17 (2013).CrossRefGoogle Scholar
7. Wu, H. and Guo, L., “Machinability of Titanium alloy TC21 under orthogonal turning process,” Materials and Manufacturing Processes, 29, pp. 1441–1445 (2014).Google Scholar
8. Ijaz, H., Zain-ul-abdein, M., Saleem, W., Asad, M. and Mabrouki, T., “A numerical approach on parametric sensitivity analysis for an aeronautic aluminium alloy turning process,” Mechanika, 22, doi: http://dx.doi.org/10.5755/j01.mech.22.2.12825 (2016).Google Scholar
9. Liu, K. and Melkote, S. N., “Finite element analysis of the influence of tool edge radius on size effect in orthogonal micro-cutting process,” International Journal of Mechanical Sciences, 49, pp. 650–660 (2007).Google Scholar
10. Lai, X., Li, H., Li, C., Lin, Z. and Ni, J., “Modelling and analysis of micro scale milling considering size effect, micro cutter edge radius and minimum chip thickness,” International Journal of Machine Tools and Manufacture, 48, pp. 1–14 (2008).Google Scholar
11. Subbiah, S. and Melkote, S. N., “Effect of finite edge radius on ductile fracture ahead of the cutting tool edge in micro-cutting of Al2024-T3,” Materials Science and Engineering: A, 474, pp. 283–300 (2008).Google Scholar
12. Meng, Q. and Wang, Z., “Extended finite element method for power-law creep crack growth,” Engineering Fracture Mechanics, 127, pp. 148–160 (2014).Google Scholar
13. Ijaz, H., Asad, M., Gornet, L. and Alam, S. Y., “Prediction of delamination crack growth in carbon/fiber epoxy composite laminates using non-local interface damage model,” Mechanics & Industry, 15, pp. 293–300 (2014).Google Scholar
14. Johnson, G. R. and Cook, W. H., “Fracture characteristics of three metals subjected to various strains, strain rates, temperatures and pressures,” Engineering Fracture Mechanics, 21, pp. 31–48 (1985).Google Scholar
15. Zhang, Y., Outeiro, J. C. and Mabrouki, T., “On the selection of Johnson-Cook constitutive model parameters for Ti-6Al-4 V using three types of numerical models of orthogonal cutting,” Procedia CIRP, 31, pp. 112–117 (2015).Google Scholar
16. Shrot, A. and Baker, M., “Determination of Johnson-Cook parameters from machining simulations,” Computational Materials Science, 52, pp. 298–304 (2012).Google Scholar
17. Asad, M., “Elaboration of concepts and methodologies to study peripheral down-cut milling process from macro-to-micro scales,” PhD Dissertation, INSALyon, France (2010).Google Scholar
18. Mabrouki, T., Girardin, F., Asad, M. and Rigal, J.-F., “Numerical and experimental study of dry cutting for an aeronautic aluminium alloy (A2024-T351),” International Journal of Machine Tools & Manufacture, 48, pp. 1187–1197 (2008).Google Scholar
19. Han, Z. Y., Huang, X. G., Cao, Y. G. and Xu, J. Q., “A non linear cumulative evolution model for corrosion fatigue damage,” Journal of Zhejiang University Science A, 15, pp. 447–453 (2014).Google Scholar
20. Hillerborg, A., Modeer, M. and Petersson, P. -E., “Analysis of crack formation and crack growth in concrete by means of fracture mechanics and finite elements,” Cement & Concrete Research, 6, pp. 773–781 (1976).CrossRefGoogle Scholar
21. Shi, J. and Liu, C. R., “On predicting chip morphology and phase transformation in hard machining,” The International Journal of Advanced Manufacturing Technology, 27, pp. 645–654 (2006).Google Scholar
22. Hansen, N., “The effect of grain size and strain on the tensile flow stress of aluminium at room temperature,” Acta Metallurgica, 25, pp. 863–869 (1977).Google Scholar
23. Simar, A. et al., “Integrated modeling of 6xxx series Al alloys: process, microstructure and properties,” Progress in Materials Science, 57, pp. 95–183 (2012).Google Scholar
24. Deschamps, A. and Brechet, Y., “Influence of predeformation and ageing of Al–Zn–Mg alloy—II. Modeling of precipitation kinetics and yield stress,” Acta Materialia, 4, pp. 293–305 (1999).Google Scholar
25. Zain-ul-abdein, M. and Nélias, D., “Effect of coherent and incoherent precipitates upon the stress and strain fields of 6xxx aluminium alloys: a numerical analysis,” International Journal of Mechanics and Materials in Design, 12, pp. 255–271 (2016).Google Scholar
26. Zhang, X., Wu, S., Wang, H. and Liu, C. R., “Predicting the Effects of Cutting Parameters and Tool Geometry on Hard Turning Process Using Finite Element Method,” Journal of Manufacturing Science and Engineering, 133, 041010 (2011).Google Scholar
27. Li, K., Gao, X.-L. and Sutherland, J. W., “Finite element simulation of the orthogonal metal cutting process for qualitative understanding of the effects of crater wear on the chip formation process,” Journal of Materials Processing Technology, 127, pp. 309–324 (2002).CrossRefGoogle Scholar
28. Deng, W. J. et al., “Thermal stability of ultrafine grained aluminium alloy prepared by large strain extrusion machining,” Materials Science and Technology, 30, pp. 850–859 (2014).Google Scholar
29. Knovel: Engineering Technical Reference Information, http://www.knovel.com (2008).Google Scholar