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Title:
Finite Element Modeling and Analysis of Cryogenic Machining
PI: I.S. Jawahir
Co-PI: O. W. Dillon, K.E. Rouch
Graduate Student: I.H. Jaafar
Sponsor: US Department of Education (GAANN Fellowship)
Abstract
The research is aimed at finite element modeling and analysis of cryogenic machining. FE models that were developed by previous research group members will be extended to the case of cryogenic cooling application in metal cutting. The earlier model used a Johnson-Cook fracture strain criterion for chip breaking and for the prediction of potential crack locations. Subsequent work then utilized a modified Thomason void coalescence criterion for predicting fracture. Previous research also developed an FE program to model the residual stresses induced in orthogonal cutting with a finite cutting edge radius tool that utilized a material model sensitive to variations in cutting rate, work hardening, and cutting temperature . This program was also later used to compare FE simulated data with experimental temperature distributions recorded from orthogonal cutting with a rounded cutting edge radius grooved tool. The present work aims to continue these earlier developments by studying the role of void nucleation, growth, and coalescence in orthogonal chip formation for a given material and how the evolution of these voids are affected at cryogenic temperatures. The effect of these voids as they coalesce and turn up at the machined surface on residual stresses will also studied. The final output of the research would be a finite element model and program that successfully incorporates these factors in orthogonal metal cutting at cryogenic temperatures.
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