Cutting process modeling is still a significant challenge due to the severe plastic deformation of the workpiece and intense friction between the workpiece and tool. Nowadays, a novel experimental approach based on digital image correlation (DIC) technique has been utilized to study the severe deformation of the workpiece. However, the experimentally measured velocity field does not necessarily satisfy the equilibrium equation that is one of the fundamental governing equations in solid mechanics due to the measurement errors; hence, accurate stress fields could hardly be derived. In this paper, we propose a hybrid DIC-FEM approach to optimize the velocity field and generate a stress field that is in an equilibrium state. First, the analysis region for finite element modeling (FEM) is selected according to the captured image, and the DIC results are used to track the deformation history of the material points. Secondly, the deviatoric stresses of the analysis region are calculated by employing the plastic theory. Thirdly, the hydrostatic pressures are acquired through solving over-constrained equations derived through FEM. Finally, the velocity field is optimized to satisfy the equilibrium equation and the boundary conditions (BCs) with the DIC results serving as an initial value of the workpiece velocity field. To validate this approach, the deformations including the velocity and strain yielded by the hybrid method are compared with the DIC results. The stress fields are presented to demonstrate the satisfaction of the equilibrium equation and the BCs. Moreover, cutting forces calculated through the integration of the stress tensors are compared against the FEM simulations and the experimental measurement.
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April 2018
Research-Article
Hybrid Digital Image Correlation–Finite Element Modeling Approach for Modeling of Orthogonal Cutting Process
Dong Zhang,
Dong Zhang
State Key Laboratory of Digital Manufacturing
Equipment and Technology,
Huazhong University of
Science and Technology,
Wuhan 430074, China
Equipment and Technology,
Huazhong University of
Science and Technology,
Wuhan 430074, China
Search for other works by this author on:
Xiao-Ming Zhang,
Xiao-Ming Zhang
State Key Laboratory of Digital Manufacturing
Equipment and Technology,
Huazhong University of
Science and Technology,
Wuhan 430074, China
e-mails: zhangxm.duyi@gmail.com;
cheungxm@hust.edu.cn
Equipment and Technology,
Huazhong University of
Science and Technology,
Wuhan 430074, China
e-mails: zhangxm.duyi@gmail.com;
cheungxm@hust.edu.cn
Search for other works by this author on:
Han Ding
Han Ding
State Key Laboratory of Digital Manufacturing
Equipment and Technology,
Huazhong University of
Science and Technology,
Wuhan 430074, China
Equipment and Technology,
Huazhong University of
Science and Technology,
Wuhan 430074, China
Search for other works by this author on:
Dong Zhang
State Key Laboratory of Digital Manufacturing
Equipment and Technology,
Huazhong University of
Science and Technology,
Wuhan 430074, China
Equipment and Technology,
Huazhong University of
Science and Technology,
Wuhan 430074, China
Xiao-Ming Zhang
State Key Laboratory of Digital Manufacturing
Equipment and Technology,
Huazhong University of
Science and Technology,
Wuhan 430074, China
e-mails: zhangxm.duyi@gmail.com;
cheungxm@hust.edu.cn
Equipment and Technology,
Huazhong University of
Science and Technology,
Wuhan 430074, China
e-mails: zhangxm.duyi@gmail.com;
cheungxm@hust.edu.cn
Han Ding
State Key Laboratory of Digital Manufacturing
Equipment and Technology,
Huazhong University of
Science and Technology,
Wuhan 430074, China
Equipment and Technology,
Huazhong University of
Science and Technology,
Wuhan 430074, China
1Corresponding author.
Manuscript received June 21, 2017; final manuscript received December 22, 2017; published online February 15, 2018. Assoc. Editor: Radu Pavel.
J. Manuf. Sci. Eng. Apr 2018, 140(4): 041018 (14 pages)
Published Online: February 15, 2018
Article history
Received:
June 21, 2017
Revised:
December 22, 2017
Citation
Zhang, D., Zhang, X., and Ding, H. (February 15, 2018). "Hybrid Digital Image Correlation–Finite Element Modeling Approach for Modeling of Orthogonal Cutting Process." ASME. J. Manuf. Sci. Eng. April 2018; 140(4): 041018. https://doi.org/10.1115/1.4038998
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