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Modeling the Sliding of a Hard Wedge on a Metal Substrate

Modeling the Sliding of a Hard Wedge on a Metal Substrate. Ernesto Gutierrez- Miravete Rensselaer at Hartford CCAT- Summer 2010. Problem Description.

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Modeling the Sliding of a Hard Wedge on a Metal Substrate

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  1. Modeling the Sliding of a Hard Wedge on a Metal Substrate Ernesto Gutierrez-Miravete Rensselaer at Hartford CCAT- Summer 2010

  2. Problem Description • A hard, rigid carbide wedge (semi-angle = a) moving at constant speed V encounters a metal block (breadth =b, hardness = H) and begins to slide over its surface to a certain depth = d, under plane strain conditions for a total sliding length = L. • Initially, a prow forms in front of the sliding wedge and is pushed by it (plowing). • The prow grows in size and eventually may transform into a chip that is in turn ejected in front of the wedge (cutting).

  3. Plowing vs Cutting

  4. Friction Coefficient due to Plastic Deformation during Plowing • Tangential Force: Ft = H d b • Normal Force: Fn = H d b tan a • Friction Coefficient: m = Ft/Fn = cot a • For the case herein considered a = 45 degrees so m = 1

  5. Finite Element Model • AdvantEdge (Third Wave Systems Inc.) is a commercial implementation of the finite element method designed to analyze the behavior of metals encountered during machining operations • The code embodies an explicit scheme capable of modeling coupled, non-linear thermo-mechanics at large strains and strain rates incorporating constitutive deformation behavior, contact, friction, fracture and adaptive meshing.

  6. Systems Investigated • The following alloy systems were investigated. The material property databases included in the software were used. The value of the friction coefficient in the code was set to 0. Al-6061-T6 1020 Steel Cu-37700 Brass Ti6Al4V • Other parameter values were as follows: d = 0.005 mm; V = 10 m/s; L = 0.1 mm

  7. Results- Al6061

  8. Results –1020 Steel

  9. Results – Cu 37700

  10. Results – Ti6Al4V

  11. Summary • In all cases considered, the computed normal forces were larger than the tangential forces. • Friction coefficient values calculated from the computed forces where in all cases within 10-20% of the expected value of 1. • Both, tangential and normal forces obtained under cutting conditions decreased to about ~80% of their values exhibited during plowing conditions. • The point of transition from plowing to cutting is material dependent.

  12. Modeling the Sliding of a Hard WedgeErnesto Gutierrez-MiraveteRensselaer-Hartford

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