Friction Model Study Of Two-dimensional Cutting Simulation Based On ABAQUS

Due to the advanced computational technology, Finite Element Modeling(FEM) is being used to optimize metal cutting processes. The physical simulation of cutting process can predict physical variables such as the cutting force and temperature, residual stress of work-piece and chip morphology. A better understanding of friction modeling is required in order to produce better FEM models to support the goals of more precisely modeling the cutting process.The finite element software ABAQUS was used to establish the two-dimension orthogonal friction mode of Ti-6Al-4V established through the simplifying of three-dimensional cylindrical turning process. The major research works are included as follows:1. Based on the study of tool-chip contact state in the process of metal cutting, the friction model subroutine of shear sliding and variable friction coefficient related to the temperature were wrote using Fortran language, under ABAQUS simulation software and its secondary development platform VFRIC. At the same time, three kinds of friction model were described on the mechanism and application scope.2. The material constitutive model, choices of friction model, boundary conditions, separation criterion, etc were briefly described in two-dimension simulation modeling The errors of main cutting force and cutting temperature under different cutting conditions were contrastive analyzed between the experiment data and the simulation results of three friction model. At the same time, the rule of cutting temperature and main cutting force changing with cutting speed and feed were analyzed.3. Based on the study of the mechanism of chip formation and the chip type in metal cutting process, the formation process of titanium alloy serrated chip were analyzed, combining with aberration nephogram and cutting force curve corresponding time. The differences of chip morphology under different cutting speeds were compared between the experiments and three types of friction model. At the same time the pitch, the coefficient of and shear angle under different cutting speeds were contrastive analyzed, between the experiment and simulation of three kinds of friction model At last the difference of three kinds of friction model were evaluated.