Study on damage behavior of carbide tool for milling difficult-to-machine material

2018 ◽  
Vol 233 (2) ◽  
pp. 735-747
Author(s):  
Yao-Nan Cheng ◽  
Wan-Ying Nie ◽  
Rui Guan ◽  
Wei-Kun Jia ◽  
Fu-gang Yan
Keyword(s):  
Failure Modes ◽  
Impact Load ◽  
Impact Damage ◽  
High Plasticity ◽  
Carbide Tool ◽  
Machine Material ◽  
Tool Failure ◽  
Damage Behavior ◽  
Tool Damage ◽  
The Impact

Water chamber head is an important component of nuclear power unit, and the main material is 508 III steel of difficult-to-machine material, which has the characteristics of high hardness, high strength, high plasticity and high profile shrinkage, etc. During the milling process, the tool is subjected to the cyclic impact load, which make cutting force and cutting heat change violent and occurrence of tool damage failure accelerate. In this paper, the damage behavior of carbide tool for milling difficult-to-machine material is studied first, and then field experiment was carried out on 508 III steel material, tool failure modes were analyzed, which include impact damage and fatigue fracture, and the failure theory and the crack propagation of carbide material were investigated in the process of tool damage. Then, the impact damage model of carbide tool is established based on the classical strength theory, and the critical condition of impact damage is determined according to simulation analysis. Finally, the theoretical model of carbide tool fatigue life is established and the tool fatigue limit is analyzed. Theoretical basis and technical support are provided for the tool failure mechanisms analysis, life prediction, parameter optimization, tool design and development aspects during the study.

scholarly journals Falling Weight Impact Damage Characterisation of Flax and Flax Basalt Vinyl Ester Hybrid Composites

Polymers ◽  
2020 ◽  
Vol 12 (4) ◽  
pp. 806 ◽  
Author(s):  
Hom Nath Dhakal ◽  
Elwan Le Méner ◽  
Marc Feldner ◽  
Chulin Jiang ◽  
Zhongyi Zhang
Keyword(s):  
Vinyl Ester ◽  
Failure Modes ◽  
Hybrid Composites ◽  
Impact Damage ◽  
Matrix Cracking ◽  
Damage Mechanisms ◽  
Pull Out ◽  
Weight Impact ◽  
Falling Weight ◽  
The Impact

Understanding the damage mechanisms of composite materials requires detailed mapping of the failure behaviour using reliable techniques. This research focuses on an evaluation of the low-velocity falling weight impact damage behaviour of flax-basalt/vinyl ester (VE) hybrid composites. Incident impact energies under three different energy levels (50, 60, and 70 Joules) were employed to cause complete perforation in order to characterise different impact damage parameters, such as energy absorption characteristics, and damage modes and mechanisms. In addition, the water absorption behaviour of flax and flax basalt hybrid composites and its effects on the impact damage performance were also investigated. All the samples subjected to different incident energies were characterised using non-destructive techniques, such as scanning electron microscopy (SEM) and X-ray computed micro-tomography (πCT), to assess the damage mechanisms of studied flax/VE and flax/basalt/VE hybrid composites. The experimental results showed that the basalt hybrid system had a high impact energy and peak load compared to the flax/VE composite without hybridisation, indicating that a hybrid approach is a promising strategy for enhancing the toughness properties of natural fibre composites. The πCT and SEM images revealed that the failure modes observed for flax and flax basalt hybrid composites were a combination of matrix cracking, delamination, fibre breakage, and fibre pull out.

Fatigue Behavior of Impacted Plain-Weave Glass/Epoxy Composites under Tensile Fatigue Loading

2005 ◽  
Vol 297-300 ◽  
pp. 1291-1296 ◽  
Author(s):  
Ki Weon Kang ◽  
Jung Kyu Kim ◽  
Heung Seob Kim
Keyword(s):  
Fatigue Life ◽  
Impact Damage ◽  
Fatigue Behavior ◽  
Fatigue Loading ◽  
Epoxy Composites ◽  
Low Velocity Impact ◽  
Low Velocity ◽  
Damage Behavior ◽  
Plain Weave ◽  
The Impact

The goals of this paper are to identify the impact damage behavior of plain-weave E-glass/epoxy composites and predict the fatigue life of the composites with impact-induced damage under constant amplitude loading. To identify these behaviors, the low velocity impact and fatigue after impact tests are performed for glass/epoxy composites having two types of fiber orientations. The impact damage behavior is dependent on the fiber orientation of the composites. The fatigue life of the impacted composites can be identified through the prediction model, which was proposed on the carbon/epoxy laminates by authors regardless of fiber orientations.

Tool Pre-Failure Monitoring in Intermittent Cutting Operations

2016 ◽  
Author(s):  
M. Hassan ◽  
A. Sadek ◽  
A. Damir ◽  
M. H. Attia ◽  
V. Thomson
Keyword(s):  
Tool Wear ◽  
Failure Modes ◽  
Impact Load ◽  
Research Work ◽  
Unstable Crack ◽  
Tool Failure ◽  
Milling Operations ◽  
High Feed ◽  
Rough Milling ◽  
Intermittent Cutting

Tool failure remains one of the most challenging phenomena in machining that affects the productivity and product quality, and hence the cost. In high feed rough milling operations of hard-to-cut materials, chipping and breakage have been observed as the dominant failure modes of the end mill cutters. Most of the work in the open literature is focusing on either detecting the complete tool breakage after it takes place or detecting the progressive tool wear. Detecting the abrupt/sudden tool failure due to tool chipping before it takes place, which is essential to avoid any damage to the machined part, has not been addressed. Therefore, the main objective of this research work is to investigate the ability of using the process monitoring signals in order to detect the tool pre-failure and failure by chipping/breakage in intermittent cutting operations. A method was devised to induce impact load on the cutting tool tip to study the features of signals collected by various sensors due to unstable crack propagation and chipping, while ensuring minimal tool wear effect. The acoustic emission (AE) signal features were able to successfully capture tool pre-failure, while other signals could detect the failure occurrence only.

Impact Damage Monitoring in Composite Plates

2004 ◽  
Author(s):  
Frank J. Shih ◽  
Sauvik Banerjee ◽  
Ajit K. Mal
Keyword(s):  
Impact Load ◽  
Impact Damage ◽  
Composite Plates ◽  
Impact Testing ◽  
Far Field ◽  
Internal Damage ◽  
Distributed Sensors ◽  
Surface Motion ◽  
Impact Monitoring ◽  
The Impact

This paper is concerned with the real-time detection of internal damage in composite structural components during impact using the far-field surface motion generated by these events. Impact tests are carried out on graphite epoxy composite plates using an instrumented impact testing system. Contact force and surface motion are measured at several locations on the plate surface. The far-field surface motions, both flexural and extensional waves in the composite plate, are modeled using both approximate and exact solution methods. Postimpact test were performed to determine the extent of internal damage caused by the impact load. Further research on the detection method can lead to the development of a viable impact monitoring system for composite aerospace structures using distributed sensors.

Impact Response and Simulation of Damaged Ulna With Internal Fixation

2012 ◽  
Vol 28 (3) ◽  
pp. 324-334
Author(s):  
Cameron Coates ◽  
Priya Goeser ◽  
Camille Coates-Clark ◽  
Mark Jenkins
Keyword(s):  
Impact Test ◽  
Impact Load ◽  
Impact Damage ◽  
Dynamic Compression ◽  
Dynamic Strain ◽  
Fe Model ◽  
Transverse Impact ◽  
Case Scenario ◽  
Worst Case ◽  
The Impact

The objectives of this work were to explore a methodology that combines static and dynamic finite element (FE) analysis, linear elastic fracture mechanics (LEFM) and experimental methods to investigate a worst-case scenario in which a previously damaged bone plate system is subjected to an impact load. Cadaver ulnas with and without midshaft dynamic compression plates are subjected to a static three-point bend test and loaded such that subcritical crack growth occurs as predicted by a hybrid method that couples LEFM and static FE. The plated and unplated bones are then unloaded and subsequently subjected to a midshaft transverse impact test. A dynamic strain-based FE model is also developed to model the midshaft transverse impact test. The average value of the impact energy required for failure was observed to be 10.53% greater for the plated set. There appears to be a trade-off between impact damage and impact resistance when ulnas are supported by fixation devices. Predictions from the dynamic FE model are shown to corroborate inferences from the experimental approach.

A damage mechanics model for low-velocity impact damage analysis of composite laminates

2017 ◽  
Vol 121 (1238) ◽  
pp. 515-532 ◽  
Author(s):  
N. Li ◽  
P.H. Chen ◽  
Q. Ye
Keyword(s):  
Composite Laminates ◽  
Damage Mechanics ◽  
Failure Modes ◽  
Impact Damage ◽  
Matrix Cracking ◽  
Low Velocity Impact ◽  
Fracture Plane ◽  
Low Velocity ◽  
Velocity Impact ◽  
The Impact

ABSTRACTA method was developed to predict numerically the damage of composite laminates with multiple plies under low-velocity impact loading. The Puck criterion for 3D stress states was adopted to model the intralaminar damage including matrix cracking and fibre breakage, and to obtain the orientation of the fracture plane due to matrix failure. According to interlaminar delamination mechanism, a new delamination criterion was proposed. The influence of transverse and through-thickness normal stress, interlaminar shear stress and damage conditions of adjacent plies on delamination was considered. In order to predict the impact-induced damage of composite laminates with more plies quickly and efficiently, an approach, which can predict the specific damage of several plies in a single solid element, was proposed by interpolation on the strains of element integration points. Moreover, the proposed model can predict specific failure modes. A good agreement between the predicted delamination shapes and sizes and the experimental results shows correctness of the developed numerical method for predicting low-velocity impact damage on composite laminates.

Impact Damage Behavior of Glass/Epoxy Laminates for Railway Vehicle at Low Temperature

2006 ◽  
Vol 326-328 ◽  
pp. 1793-1796
Author(s):  
Ki Weon Kang ◽  
Seung Yong Yang ◽  
J.H. Kim ◽  
Jung Kyu Kim ◽  
Heung Seob Kim ◽  
...  
Keyword(s):  
Composite Laminates ◽  
Impact Damage ◽  
Testing Machine ◽  
Impact Testing ◽  
Low Velocity Impact ◽  
Railway Vehicle ◽  
Low Velocity ◽  
Damage Resistance ◽  
Damage Behavior ◽  
The Impact

This paper deals with the damage behavior of glass/epoxy composite laminates subjected to low-velocity impact at various temperatures. For this goal, the impact tests were performed by using an instrumented impact-testing machine at three temperatures: +20°C, -10°C and -40°C. And the resultant damages were inspected through the scanning acoustic microscope (SAM). Also, based on the impact force history and the damage configuration of the laminates, the impact resistance parameters were employed to evaluate damage resistance of glass/epoxy laminates. As results, it was found that the temperature changes affect the damage resistance capacity of glass/epoxy laminates.

Comparison of Low-Velocity Impact Damage Behavior of Unidirectional Carbon Fiber-Reinforced Thermoset and Thermoplastic Composites

2019 ◽  
Vol 809 ◽  
pp. 9-14
Author(s):  
Florian Schimmer ◽  
Sven Ladewig ◽  
Nicole Motsch ◽  
Joachim M. Hausmann ◽  
Ingo Ehrlich
Keyword(s):  
Cross Sections ◽  
Impact Damage ◽  
Test Methods ◽  
Impact Testing ◽  
Low Velocity Impact ◽  
Thermoplastic Composites ◽  
Fiber Reinforced ◽  
Low Velocity ◽  
Damage Behavior ◽  
The Impact

This paper investigates the damage behavior of thermoset and thermoplastic fiber-reinforced composites. The specimens were subjected to low-velocity impacts (LVI) to produce barely visible impact damages (BVID). To compare the dependency of the matrix system and the laminate lay-up on the impact damage, four test series were set up. Therefore, laminates with an epoxy (EP) and a polyether ether ketone (PEEK) matrix in a quasi-isotropic (QI) [+45/0/-45/90]2s and an orthotropic (OT) fiber lay-up [0/90]4s were manufactured. To eliminate the influence of variant fiber systems, the thermoplastic tape and the thermoset prepreg contain similar carbon fibers (CF). After impact testing with three different impact energies, inner damages were investigated by using ultrasonic analyses. To get a deeper understanding of the interior damage mechanisms, cross sections of the damaged areas were examined via reflected light microscopy. By using these destructive and non-destructive test methods, significant differences in the damage behavior of composites with thermoplastic and thermoset matrix systems were identified for both laminate lay-ups.

Impact Damage Behavior of Composite Stiffened Plates

2011 ◽  
Vol 117-119 ◽  
pp. 954-957
Author(s):  
Li Yan ◽  
Xue Feng An ◽  
Chen Qian Zhang ◽  
Xiao Su Yi
Keyword(s):  
Impact Damage ◽  
Visual Observation ◽  
Impact Testing ◽  
Low Velocity Impact ◽  
Stiffened Plates ◽  
Low Velocity ◽  
Damage Behavior ◽  
Damage Area ◽  
Impact Position ◽  
The Impact

Damage behavior of composite stiffened plates of structure I and structure II at different positions and under different impact energy subjected to low-velocity impact testing was studied in this paper. Visual observation and ultrasonic C-scanning were also employed to inspect the damage size. The results showed that damage behavior of composite stiffened plates was not only related to damage behavior of laminates, but also related to damage between stringer and laminate and damage of stringer itself. It was found that the mechanism of absorbing energy varies with the impact position, as well as the damage behavior. When the impact position was near stringer, partial energy was absorbed by stringer to make stringer and laminate disengage and damage area of laminates was smaller. Damage behavior of composite stiffened plates varies with the structure. Damage area of samples of structure II was smaller than that of samples of structure I. It was estimated preliminarily that design of structure II was better than that of structure I.

Determination of the Fatigue Behavior of Aluminide Coatings by Means of the Impact Testing Method

2007 ◽  
Vol 348-349 ◽  
pp. 645-648
Author(s):  
Kostas David ◽  
K.G. Anthymidis ◽  
P. Agrianidis ◽  
D.N. Tsipas
Keyword(s):  
Fatigue Failure ◽  
Fatigue Resistance ◽  
Failure Modes ◽  
Impact Load ◽  
Fatigue Behavior ◽  
Impact Testing ◽  
Testing Method ◽  
Aluminide Coatings ◽  
The Impact

The impact testing is an efficient experimental method that enables the quantitative and qualitative determination of the fatigue resistance of mono- and multilayer coatings deposited on various substrates, which was not possible with the common testing methods previously available. In this paper the experimental assessment of the fatigue resistance of coatings working under cyclic loading conditions by means of the dynamic impact testing method is presented. The fatigue failure mode, such cohesive or adhesive, of the investigated coatings is determined using scanning electron and optical microscopy, as well as EDX analysis. Critical values of the stress components, responsible for distinctive fatigue failure modes of the coating substrate system are obtained and the fatigue limits of aluminide coatings are illustrated in simple diagrams containing the impact load versus the number of successive impacts that the examined aluminide-P91 system can withstand.

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