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HYDERABAD CAMPUS
SECOND SEMESTER 2017-2018
MATH F266 – STUDY PROJECT
PROJECT TITLE & PLAN OF WORK
Date: 23-01-2017
Identification of Johnson-Cook Material Model parameters for high strain and strain rate
machining using Response Surface Methodology along with inverse cutting operations.
FEM is one of the important and efficient research methods in the field of machining. There has
been an immense amount of research on developing the finite element method (FEM) based on
numerical models for the simulation of machining processes. An accurate material constitutive
model is a key issue to develop a realistic finite element model of a machining operation. The
material models play a vital role in predicting chip formation, computing forces, distributions of
strain, strain rate, temperature, and stress in cutting zones. The simulation results of the
machining process are highly dependent on the constitutive model that represents the material
behavior as well as the parameters that constitute the material model. This project is aimed at
providing an inverse approach based on Response Surface Methodology to identify the material
Optimizing the JCMM parameters using the experimental conditions generated from
RSM.
4. Literature Review
Introduction:
M Daoud has used an inverse identification method based on orthogonal cutting tests to
determine the Johnson-Cook material parameters. One unique feature is the usage of response
surface methodology (RSM) as a technique to improve the existing inverse method. This
technique has been tested on a 6061T6 high strength aluminium alloy. The parameters acquired
using this technique were found to predict more accurate values of flow stress as compared to
those mentioned in the literature.
Methodology:
The author has used the common Johnson-Cook constitutive model without any modifications in
this technique. The material parameters were acquired using the inverse method. The cutting
forces and chip thickness were the input data, output data were equivalent flow stress, the plastic
equivalent strain, the equivalent strain rate, and the cutting temperature (calculated using Oxley’s
model). A nonlinear regression based on the interior point algorithm was employed to determine
the material parameters:
(A, B, n, C, m) =
The author has used the technique of Response Surface Methodology to include a large number
of cutting conditions during the optimization routine. The cutting experiments are conducted
using central composite design. A central composite design contains an imbedded factorial or
fractional factorial design with the center points that is augmented with a group of ‘star points’
that allow estimation of curvature The CCD models provide a more accurate resolution of non-
linear responses. A central composite design can be used to
1) Effectively calculate first- and second-order terms.
2) Model a response variable with curvature by adding center and axial points to a
previously done factorial design.
In this experiment, three factors are taken into consideration: rake angle (α), cutting speed (V)
and feed rate (f). This is represented graphically in space on a 3D cube by corresponding each
axis the cube to an independent factor and each point in the space to an experiment.
According to the central composite design, 16 experiments have been generated (8 factor points,
6 star points and 2 center points). The upper limit of the factor is coded as +1.68 and the lower
limit -1.68. These values were used to determine the material parameters. Four extra conditions
were left for validation purpose. With the help of RSM and CCD, a second-order model has been
developed with 95% confidence level:
where y is the corresponding response and are the values of the ith and jth machining process
parameters. The terms are the regression coefficients and the represents the
experimental error of the observations. By using the machining parameters, such as rake angle
(α), cutting speed (V) and feed rate (f). The relation between the response surface and the
machining parameters is given by:
Experimental Results:
Second-order models for cutting forces and chip thickness were developed using the
experimental results. A response surface equation that is based on CCD has been developed to
determine the cutting force, thrust force and chip thickness, which is in terms of rake angle,
cutting speed and feed rate. The coefficient of determination for all the experimental observed
values was found to between 94% and 95%. Value of adjusted coefficient of determination
is between 85% and 97%. Second order model was able to predict the cutting forces and chip
thickness in an accurate manner. The extra four machining conditions were used to validate the
model and the predicted results were in good agreement with the observed experimental values
of cutting forces, thrust force and chip thickness. The identification procedure has been
performed with 99 cutting tests.
6. References
i. Daoud, M., et al. “Identification of Material Constitutive Law Constants Using
Machining Tests: a Response Surface Methodology Based Approach.” High Performance
and Optimum Design of Structures and Materials, Sept. 2014, doi:10.2495/hpsm140031.
ii. Malakizadi, Amir, et al. “Inverse Identification of Flow Stress in Metal Cutting Process
Using Response Surface Methodology.” Simulation Modelling Practice and Theory, vol.
60, 2016, pp. 40–53., doi:10.1016/j.simpat.2015.09.009.
iii. Lesuer, D.R., Kay, G. J., LeBlanc, M. M., Modeling Large-Strain, HighRate Deformation
in Metals, Third Biennial Tri-Laboratory Engineering Conference Modeling and
Simulation, Pleasanton, CA, November 3-5, 1999, pp., 2001.
iv. Guo, Y.b. “An Integral Method to Determine the Mechanical Behavior of Materials in
Metal Cutting.” Journal of Materials Processing Technology, vol. 142, no. 1, 2003, pp.
72–81., doi:10.1016/s0924-0136(03)00462-x.
v. Dabboussi, W., Nemes, J., Modeling of ductile fracture using the dynamic punch test,
International journal of mechanical sciences, 47, pp. 1282-99, 2005.