It has long been argued about which effect, among the effects of strain hardening, strain-rate hardening, and temperature softening, is predominant in governing the material flow stress in machining. This paper presents a new quantitative sensitivity analysis of the flow stress of 18 engineering materials based on the well-known Johnson-Cook model. It is demonstrated that the first predominant factor governing the material flow stress is either strain hardening or thermal softening, depending on the specific material employed and the varying range of temperatures. Strain-rate hardening is the least important factor governing the material flow stress, especially when machining aluminum alloys.
1.
Shirakashi
, T.
, and Obikawa
, T.
, 1998
, “Recent Progress and Some Difficulties in Computational Modeling of Machining
,” Mach. Sci. Technol.
, 2
, pp. 277
–301
.2.
Liu
, C. R.
, and Guo
, Y. B.
, 2000
, “Finite Element Analysis of the Effect of Sequential Cuts and Tool-Chip Friction on Residual Stresses in a Machined Layer
,” Int. J. Mech. Sci.
, 42
, pp. 1069
–1086
.3.
Shih
, A. J.
, 1996
, “Finite Element Analysis of the Rake Angle Effects on Orthogonal Metal Cutting
,” Int. J. Mech. Sci.
, 38
, pp. 1
–17
.4.
Stevenson
, R.
, 1997
, “Study on the Correlation of Workpiece Mechanical Properties from Compression and Cutting Tests
,” Mach. Sci. Technol.
, 1
, pp. 67
–79
.5.
Stephensen
, D. A.
, 1989
, “Material Characterization for Metal-Cutting Modeling
,” ASME J. Eng. Mater. Technol.
, 111
, pp. 210
–219
.6.
Fang
, N.
, 2003
, “Slip-Line Modeling of Machining with a Rounded-Edge Tool, Part I: New Model and Theory
,” J. Mech. Phys. Solids
, 51
, pp. 715
–742
.7.
Fang
, N.
, Jawahir
, I. S.
, and Oxley
, P. L. B.
, 2001
, “A Universal Slip-Line Model With Non-Unique Solutions for Machining With Curled Chip Formation and a Restricted Contact Tool
,” Int. J. Mech. Sci.
, 43
, pp. 557
–580
.8.
van Luttervelt
, C. A.
, Childs
, T. H. C.
, Jawahir
, I. S.
, Klocke
, F.
, and Venuvinod
, P. K.
, 1998
, “Present Situation and Future Trends in Modeling of Machining Operations
,” CIRP Ann.
, 47
, pp. 587
–626
.9.
Kececioglu
, D.
, 1958
, “Shear-Strain Rate in Metal Cutting and Its Effects on Shear-Flow Stress
,” Trans. ASME
, 80
, pp. 158
–168
.10.
Kececioglu
, D.
, 1958
, “Shear-Zone Temperature in Metal Cutting and Its Effects on Shear-Flow Stress
,” Trans. ASME
, 80
, pp. 541
–546
.11.
Kececioglu
, D.
, 1960
, “Shear-Zone Size, Compressive Stress, and Shear Strain in Metal-Cutting and Their Effects on Mean Shear-Flow Stress
,” ASME J. Eng. Ind.
, 82
, pp. 79
–86
.12.
Spaans
, C.
, 1972
, “A Treatise on the Streamlines and the Stress, Strain, and Strain Rate Distribution, and on Stability in the Primary Shear Zone in Metal Cutting
,” ASME J. Eng. Ind.
, 94
, pp. 690
–696
.13.
Murarka
, P. D.
, Hinduja
, S.
, and Barrow
, G.
, 1981
, “Influence of Strain, Strain-Rate and Temperature on the Flow Stress in the Primary Deformation Zone in Metal Cutting
,” Int. J. Mach. Tool Des. Res.
, 21
, pp. 207
–216
.14.
Saltelli, A., Chan, K., and Scott, E. M., 2000, Sensitivity Analysis, Wiley, Chichester, UK.
15.
Johnson, G. R., and Cook, W. H., 1983, “A Constitutive Model and Data for Metals Subjected to Large Strains, High Strain Rates and High Temperatures,” Proc. of 7th Int. Symp. Ball., Hague, The Netherlands, pp. 541–547.
16.
Jaspers, S. P. F. C., 1999, “Metal Cutting Mechanics and Material Behavior,” Ph.D. thesis, Technical University of Eindhoven, Eindhoven, The Netherlands.
17.
Oxley, P. L. B., 1989, The Mechanics of Machining: An Analytical Approach to Assessing Machinability, Ellis Horwood Limited, Chichester, UK.
18.
Zerilli
, F. J.
, and Armstrong
, R. W.
, 1987
, “Dislocation-Mechanics-Based Constitutive Relations for Material Dynamics Calculations
,” J. Appl. Phys.
, 61
, pp. 1816
–1825
.19.
Maekawa
, K.
, Shirakashi
, T.
, and Usui
, E.
, 1983
, “Flow Stress of Low Carbon Steel at High Temperature and Strain Rate (Part 2)–Flow Stress Under Variable Temperature and Variable Strain Rate
,” Bull. Jpn. Soc. Precis. Eng.
, 17
, pp. 167
–172
.20.
Childs, T. H. C., 1998, “Material Property Needs in Modeling Metal Machining,” Proc. CIRP Int. Work. Model. Mach. Opera., Atlanta, pp. 193–202.
21.
Stevenson
, M. G.
, and Oxley
, P. L. B.
, 1970
–1971, “An Experimental Investigation of the Influence of Strain-Rate and Temperature on the Flow Stress Properties of a Low Carbon Steel Using a Machining Test
,” Proc. Inst. Mech. Eng.
, 185
, pp. 741
–754
.22.
Friedman
, J. H.
, 1991
, “Multivariate Adaptive Regression Splines
,” Ann. Stat.
, 19
, pp. 1
–67
.23.
http://www.salford-systems.com
24.
Johnson, G. R., Stryk, R. A., Holmquist, T. J., and Beissel, S. R., 1996, User Instructions for the 1996 Version of the EPIC Code, Alliant Techsystems Inc.
25.
Dannemann, K. A., Anderson, C. E., and Johnson, G. R., 2001, “Modeling the Ballistic Impact Performance of Two Aluminum Alloys,” Proc. Symp. Model. Perf. Eng. Struct. Mate. II, Indianapolis, pp. 63–74.
Copyright © 2005
by ASME
You do not currently have access to this content.
