Comparison Orthogonal Tube Turning Data Versus Finite Element Simulation Using LS Dyna

Abstract

The current study focuses on building a 2-Dimensional finite element model to simulate the orthogonal machining process under a dry machining environment in a commercially available FEA solver LS DYNA. One of the key objectives of this thesis is to carefully document the use of LS Dyna to model metal cutting, allowing other researchers to more quickly build on this work. Actual force data is obtained using an Orthogonal Tube Turning apparatus that has been statistically validated to an accuracy of 99+%. The work material used in this study is Aluminum 6061-T6 alloy. The tool material is tool steel, which is modeled as a rigid body. A Plastic Kinematic Material Hardening model is used to define the work material. Chip formation is based on the effective failure plastic strain. A constant coefficient of friction between the tool and work piece is used, obtained from the actual experimental results. The simulation is carried out with the same constant velocity, different rake angles and depth cuts as in the real world experiment. The cutting force and thrust force values obtained for each combination of rake angle and cut depth are validated against the experimental data obtained at Auburn University. The resulting model is considered valid enough to use for sensitivity analysis of the metal cutting process in aluminum alloy 6061-T6 in the university environment. The model is available publicly to any university from a website provided.