![]() In this work, the machining of ultra-fine-grained pure titanium (UFG Ti) in an integrated manufacturing process combining severe plastic deformation (SPD) process and machining process is investigated through analytical modeling with experimental validation. Considering the simple orthogonal cutting tests, reliable and easily measurable machining forces, and efficient iterative gradient search method, the proposed method has less experimental complexity and high computational efficiency. ![]() Close agreements were observed between predicted forces and experimental forces. To validate the identified J-C constants, machining forces were predicted using the identified J-C constants under different cutting conditions and then compared to the corresponding experimental forces. An iterative gradient search method was enforced to find the J-C constants when the difference between predicted forces and experimental forces reached an acceptable low value. The machining forces were also predicted using the chip formation model with inputs of cutting conditions, workpiece material properties, and a set of given model constants. In this work, multiple cutting tests were conducted under different cutting conditions, in which machining forces were experimentally measured using a piezoelectric dynamometer. Currently, the J-C constants of UFG Ti are unavailable and yet an effective identification methodology based upon machining data is not readily available. Johnson–Cook model is one of the constitutive models widely used in analytical modeling of machining force, temperature, and residual stress because it is effective, simple, and easy to use. UFG Ti is increasingly finding usefulness in lightweight engineering applications and medical implant filed because of its sufficient mechanical strength, high manufacturability, and high biocompatibility. This paper presents an original method to inversely identify the Johnson–Cook model constants (J-C constants) of ultra-fine-grained titanium (UFG Ti) based on a chip formation model and an iterative gradient search method using Kalman filter algorithm. Also, plots of horizontal and vertical components of Von Mises stress against applied forces were obtained. For these three loading scenarios, calibration plots by experiment compared with plots obtained from simulation by finite element analysis gave accuracies of 79%, 95%, 84% and 36%, 57%, 63% for vertical and horizontal deflections respectively. THE CUTTING TOOL ON THE LATHE EXERTS A FORCE PROFESSIONALBy obtaining the governing equation, modeling the dynamometer assembly, defining boundary conditions, generating the assembly mesh, and simulating in Inventor Professional horizontal and vertical components of deflection by the dynamometer were read off for three different loading scenarios. ![]() In this study, finite element analysis has been used to obtain the deflection and stress response of a two component cutting tool lathe dynamometer, for turning operation, when the cutting tool is subjected to cutting and thrust forces from 98.1N to 686.7N (10 to 70kg-wts), at intervals of 98.1N(10kg-wt). Calibration curves of a multi-component dynamometer is of essence in machining operations in a lathe machine as they serve to provide values of force and stress components for cutting tool development and optimization. ![]()
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