Mechanical micromachining is a powerful and effective way for manufacturing small sized machine parts. Even though the micromachining process is similar to the traditional machining, the material behavior during the process is much different. In particular, many researchers report that the basic mechanics of the work material is affected by microstructures and their crystallographic orientations. For example, crystallographic orientations of the work material have significant influence on force response, chip formation and surface finish. In order to thoroughly understand the effect of crystallographic orientations on the micromachining process, finite-element model (FEM) simulating orthogonal cutting process of single crystallographic material was presented. For modeling the work material, rate sensitive single crystal plasticity of face-centered cubic (FCC) crystal was implemented. For the chip formation during the simulation, element deletion technique was used. The simulation model is developed using ABAQUS/explicit with user material subroutine via user material subroutine (VUMAT). Simulations showed that variation of the specific cutting energy at different crystallographic orientations of work material shows significant anisotropy. The developed FEM model can be a useful prediction tool of micromachining of crystalline materials.
Bibliographical noteFunding Information:
The work presented here is guided by Professor O. Burak Ozdoganlar and Dr. Nithyanand Kota. Their guidance is greatly acknowledged. This research was supported in part by the National Science Foundation through Tera-Grid resources provided by Pittsburgh Supercomputing Center under Grant No. MSS110030.
© 2015 World Scientific Publishing Company.
- computer simulation
- crystal plasticity
ASJC Scopus subject areas
- Statistical and Nonlinear Physics
- Condensed Matter Physics