Challenge and problems with hybrid systems for modelling of machining operations

摘要

At present there are no suitable comprehensive theoretical models that satisfactorily describe all the mechanical and thermal features of the cutting process. Main problems are the frictional interactions between chip, tool and workpiece and the simulation of the real material behaviour. Therefore a hybrid experimental-theoretical approach seems to be a good compromise to describe these complicated correlations. The real-time measurement of mechanical and thermal parameters immediately in the small zone of plastic deformation in cutting processes is difficult. Only two-dimensional methods can give a satisfying general view of the distributions of strain, stress and temperature in the chip forming area and along the rake face of the tool. Visioplasticity is such a proved experimental method to investigate plastic deformations in machined workpieces in order to get boundary conditions as well as to verify and to improve numerical simulations by finite element analysis.