Chip formation

Algorithm

Engineering

Residual stress

Metallurgy

Materials science

Inverse

Telecommunications

Computer science

Titanium

Tool wear

Mechanical engineering

Physics

Mathematics

Geometry

Composite material

Machining

Dynamometer

Chip

Mechanics

The International Journal of Advanced Manufacturing Technology

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. 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. 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. Currently, the J-C constants of UFG Ti are unavailable and yet an effective identification methodology based upon machining data is not readily available. In this work, multiple cutting tests were conducted under different cutting conditions, in which machining forces were experimentally measured using a piezoelectric dynamometer. 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. 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. 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. Close agreements were observed between predicted forces and experimental forces. 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.

Inverse determination of Johnson–Cook model constants of ultra-fine-grained titanium based on chip formation model and iterative gradient search