Werkstoffmodellierung und Kennwertermittlung für die Simulation spanabhebender Fertigungsprozesse

Finite element simulation of machining processes enable cutting tool and process design for specific requirements of cutting applications. Applying simulation techniques leads to a reduction of real cutting experiments, development times and costs. The physical input data of a simulation is of special importance, since it significantly affects the simulation quality. Especially the material law and the material data for the approximation of the flow stress are important factors. In the research of this thesis a new method for the determination of material data, based on linear-orthogonal cutting tests, is developed. Applying optical high-speed measurements in the chip formation zone the shear strain rate in the material is determined by Digital Image Correlation (DIC). Together with the cutting forces this data is used to determine material data sets via an inverse approach. Split-Hopkinson as well as compression tests provide additional material data sets, the data is also used to evaluate the material behavior at increased strain rates and temperatures. Based on these results, a modified material law is presented, considering specific characteristics in the thermal softening curve of the steel material investigated. The material data sets and the material laws are applied in simulations and the results are compared with measurements from real cutting tests.