|About this Abstract
||NUMIFORM 2019: The 13th International Conference on Numerical Methods in Industrial Forming Processes
||S-07: Computational Modelling of Scaled Processes and Experiments
||Scaling of High Speed Chip Formation
||Keith Davey, Hamed Sadeghi, Anees Al-Tamimi, Ali Golbaf, Rooholamin Darvizeh
|On-Site Speaker (Planned)
Determining the response characteristics of a full-scale manufacturing process involving high-deformation rates by means of scaled experimentation is recognised to be difficult if not practically impossible. The principal difficulty is scale effects which can be attributed to nonlinearities arising from lengths, areas and volumes scaling at different rates. Difficulties are particularly acute for processes invoking high-deformation rates as strain-rate effects are present which are recognised to be non-scalable and consequently break similitude between a full-scale processes and small-scale experiments.
Dimensional analysis, the founding theory underpinning scaled experimentation, is limited by the need to match Pi groups (dimensionless parameters), since this match is seldom possible in realistic high-rate manufacturing processes. Dimensional analysis reveals however, that realistic full-scale and small-scale high-rate models can seldom use materials with identical properties as exact similitude does not exist. Another concern is that “identical materials” can have different material properties depending on how the material is processed, where for example a steel plate at full scale can differ materially from a steel plate at a smaller scale.
It is clear therefore that any practical scaling method must cater for scale effects and different material properties. In the presented work, a new method that has appeared in the recent literature is tested for the first time on cutting processes with a particular focus on high rates of deformation and chip formation. Revealed in the paper is the potential of the new approach for scaling high-rate cutting processes.