scholarly journals Development and validation of a meshless 3D material point method for simulating the micro-milling process

2018 ◽  
Author(s):  
Sabine Leroch ◽  
Stefan J Eder ◽  
Georg Ganzenmüller ◽  
Jose Luis Sandoval Murillo ◽  
Manel Rodriguez Ripoll
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Chip Thickness ◽  
Material Point Method ◽  
Milling Process ◽  
Material Point ◽  
Finite Element Simulations ◽  
Point Method ◽  
Micro Milling ◽  
3D Simulations

A meshless Generalized Interpolation Material Point Method for simulating the micro-milling process was developed. This method has several advantages over well-established approaches (such as finite elements) when it comes to large plastic strains and deformations, since it inherently does not suffer from tensileinstability problems. The feasibility of the developed material point model for simulating micro-milling is verified against finite element simulations and experimental data. The model is able to successfully predict experimentally measured cutting forces and determine chip temperatures in agreement with conventional finite element simulations. After having verified the approach, the model was applied to perform extensive numerical 3D simulations of the micro-milling process. The goal is to evaluate the response of the micro-milling cutting forces as function of the hardening behavior of the micro-milled material. The meshless 3D simulations reveal a dependency of tool force slopes (with respect to the uncut chip thickness) on the hard-ening parameters. Based on these findings, a new approach is outlined to determine hardening parametersdirectly from two micro-milling experiments with distinct, sufficiently large uncut chip thicknesses.

Dynamic Simulation of the Micro-Milling Process Including Minimum Chip Thickness and Size Effect

2012 ◽  
Vol 504-506 ◽  
pp. 1269-1274 ◽  
Author(s):  
François Ducobu ◽  
Edouard Rivière-Lorphèvre ◽  
Enrico Filippi
Keyword(s):  
Size Effect ◽  
Cutting Forces ◽  
Mechanistic Model ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Milling Process ◽  
Cutting Conditions ◽  
Micro Milling ◽  
Minimum Chip Thickness ◽  
Physical Phenomena

Micro-milling with a cutting tool is a manufacturing technique that allows production of parts ranging from several millimeters to several micrometers. The technique is based on a downscaling of macroscopic milling process. Micro-milling is one of the most effective process to produce complex three-dimensional micro-parts, including sharp edges and with a good surface quality. Reducing the dimensions of the cutter and the cutting conditions requires taking into account physical phenomena that can be neglected in macro-milling. These phenomena include a size effect (nonlinear rising of specific cutting force when chip thickness decreases), the minimum chip thickness (under a given dimension, no chip can be machined) and the heterogeneity of the material (the size of the grains composing the material is significant as compared to the dimension of the chip). The aim of this paper is to introduce some phenomena, appearing in micromilling, in the mechanistic dynamic simulation software ‘dystamill’ developed for macro-milling. The software is able to simulate the cutting forces, the dynamic behavior of the tool and the workpiece and the kinematic surface finish in 2D1/2 milling operation (slotting, face milling, shoulder milling,…). It can be used to predict chatter-free cutting condition for example. The mechanistic model of the cutting forces is deduced from the local FEM simulation of orthogonal cutting. This FEM model uses the commercial software ABAQUS and is able to simulate chip formation and cutting forces in an orthogonal cutting test. This model is able to reproduce physical phenomena in macro cutting conditions (including segmented chip) as well as specific phenomena in micro cutting conditions (minimum chip thickness and size effect). The minimum chip thickness is also taken into account by the global model. The results of simulation for the machining of titanium alloy Ti6Al4V under macro and micro milling condition with the mechanistic model are presented discussed. This approach connects together local machining simulation and global models.

Cutting forces analysis of micro-milling process on Inconel 718 – a finite element approach

2020 ◽  
Vol 11 (02) ◽  
pp. 2050011
Author(s):  
Padmaja Tripathy ◽  
Kalipada Maity
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Fem Analysis ◽  
Milling Process ◽  
Machining Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Parameters

This paper presents a modeling and simulation of micro-milling process with finite element modeling (FEM) analysis to predict cutting forces. The micro-milling of Inconel 718 is conducted using high-speed steel (HSS) micro-end mill cutter of 1mm diameter. The machining parameters considered for simulation are feed rate, cutting speed and depth of cut which are varied at three levels. The FEM analysis of machining process is divided into three parts, i.e., pre-processer, simulation and post-processor. In pre-processor, the input data are provided for simulation. The machining process is further simulated with the pre-processor data. For data extraction and viewing the simulated results, post-processor is used. A set of experiments are conducted for validation of simulated process. The simulated and experimental results are compared and the results are found to be having a good agreement.

The flank wear prediction in micro-milling Inconel 718

2018 ◽  
Vol 70 (8) ◽  
pp. 1374-1380 ◽  
Author(s):  
Xiaohong Lu ◽  
FuRui Wang ◽  
Zhenyuan Jia ◽  
Steven Y. Liang
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Flank Wear ◽  
Milling Process ◽  
Micro Milling ◽  
Wear Prediction ◽  
Content Type ◽  
Micro Tool

Purpose Cutting tool wear is known to affect tool life, surface quality, cutting forces and production time. Micro-milling of difficult-to-cut materials like Inconel 718 leads to significant flank wear on the cutting tool. To ensure the respect of final part specifications and to study cutting forces and tool catastrophic failure, flank wear (VB) has to be controlled. This paper aims to achieve flank wear prediction during micro-milling process, which fills the void of the commercial finite element software. Design/methodology/approach Based on tool geometry structure and DEFORM finite element simulation, flank wear of the micro tool during micro-milling process is obtained. Finally, experiments of micro-milling Inconel 718 validate the accuracy of the proposed method for predicting flank wear of the micro tool during micro-milling Inconel 718. Findings A new prediction method for flank wear of the micro tool during micro-milling Inconel 718 based on the assumption that the wear volume can be assumed as a cone-shaped body is proposed. Compared with the existing experiment techniques for predicting tool wear during micro-milling process, the proposed method is simple to operate and is cost-effective. The existing finite element investigations on micro tool wear prediction mainly focus on micro tool axial wear depth, which affects size accuracy of machined workpiece seriously. Originality/value The research can provide significant knowledge on the usage of finite element method in predicting tool wear condition during micro-milling process. In addition, the method presented in this paper can provide support for studying the effect of tool flank wear on cutting forces during micro-milling process.

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