|
vc
|
Cutting speed (m/min) |
vf
|
Direction of feed motion |
|
ap, DA(CB) |
Depth of cut (mm) |
A |
Yield strength (MPa) |
|
f, CH(DG) |
Feed rate (mm/rev) |
B |
Strain hardening coefficient (MPa) |
| FEM |
Finite element model |
C |
Strain rate hardening coefficient |
| F |
Cutting force (N) |
m |
Thermal softening exponent |
| Fc
|
Circumferential force (N) |
n |
Strain hardening exponent |
| Fr
|
Radial force (N) |
S1
|
Projection area of chip and rake face contact surfaces on the base plane |
| Fa
|
Axial force (N) |
S2
|
Projection area of chip and rake face contact surfaces on the working plane |
|
Pr, ADGE |
Base plane |
S3
|
Projection area of chip and rake face contact surfaces on the back plane |
|
Ps, |
Cutting plane |
T
|
Temperature (°C) |
|
Po, |
Orthogonal plane |
Troom
|
Room temperature (°C) |
|
Pp, ABCD |
Back plane |
Tmelt
|
Melting temperature (°C) |
|
Pf, CDGH |
Working plane |
B
0
|
Coefficient of temperature and cutting speed term |
| 3D |
Three-dimensional |
|
κr
|
Tool cutting-edge angle (°) |
B1~B3
|
Coefficients of cutting forces, cutting, and tool parameters’ terms |
|
γ0
|
Rake angle (°) |
m1, m2
|
Exponents of temperature and cutting speed terms |
|
λs
|
Inclination angle (°) |
n1~n6
|
Exponents of cutting forces, cutting, and tool parameters’ terms |
|
γp, ∠MDA |
Back-rake angle (°) |
N
|
Total of simulations (N = 24) |
|
γf, ∠NDG |
Side-rake angle (°) |
i
|
The ith simulation (I = 1, 2, ⋯, N.) |
|
R
|
Correlation coefficient |
AARE |
Absolute average error |
|
|
Equivalent plastic strain |
|
Equivalent plastic stress (MPa) |
|
|
Equivalent plastic strain rate () |
|
Reference equivalent plastic strain rate () |
|
|
Surface residual stress |
|
Stress component caused by Fc applying to S1
|
|
|
Stress component caused by Fr applying to S2
|
|
Stress component caused by Fa applying to S3
|
|
|
Stress component relevant to thermal effect |
|
Part of surface residual stress relevant to cutting temperature and cutting speed |
|
|
Mean of all 24 simulated residual stresses on the surface |
|
Part of surface residual stress relevant to cutting force, feed, cutting depth, and tool angle |
|
|
The ith simulated residual stress on the surface |
|
The predicted residual stress on the surface for the ith simulation |
|
|
Optimization objective |
|
Mean of all 24 predicted residual stresses on the surface |