scholarly journals Analyzing the Effect of Particle Shape on Deformation Mechanism during Cutting Simulation of SiC P/Al Composites

Micromachines ◽  
2021 ◽  
Vol 12 (8) ◽  
pp. 953
Author(s):  
Jiakang Zhou ◽  
Jieqiong Lin ◽  
Mingming Lu ◽  
Xian Jing ◽  
Yubo Jin ◽  
...  
Keyword(s):  
Cutting Force ◽  
Chip Formation ◽  
Particle Shape ◽  
Metal Matrix ◽  
Phase Particle ◽  
Particle Model ◽  
Fe Model ◽  
Cutting Simulation ◽  
Polygonal Particle ◽  
The Impact

To analyze the effect of particle shape on deformational behavior in the cutting simulation process for metal matrix composites (MMCs), two 2D mesoscopic-based finite element (FE) models reinforced with randomly distributed circular and irregular polygonal particles were developed. Different material properties (metal matrix phase, particle reinforced phase) and the properties of the particle–matrix interface were comprehensively considered in the proposed FE model. Systematic cutting experiments were conducted to compare the differences between two modeling approaches with respect to particle fracture, chip formation, cutting force and surface integrity. The results show that the irregular polygonal particle model is closer to the microstructure of MMCs, and is better able to reflect the deformation behavior of particles. The simulation model with irregular polygonal particles is even able to capture more details of the impact caused by particles, reflecting variations in the cutting force in the actual cutting process. The initiation and propagation of microcracks is mainly determined on the basis of particle geometry and further affects chip formation. Both models are able to correctly reflect surface defects, but the irregular polygonal particle model provides a more comprehensive prediction for the subsurface damage of MMCs.

scholarly journals Experimental Investigation and Numerical Prediction of the Effects of Cutting Tool Geometry During Turning of AISI 316L Steel

2021 ◽  
Vol 65 (4) ◽  
pp. 293-301
Author(s):  
Amor Benmeddour
Keyword(s):  
Temperature Distribution ◽  
Residual Stresses ◽  
Cutting Force ◽  
Rake Angle ◽  
Tool Geometry ◽  
Model Parameters ◽  
Fe Model ◽  
Aisi 316L ◽  
Arbitrary Lagrangian Eulerian ◽  
The Impact

In this work, a numerical and an experimental study aimed to gain a better understanding of the impact of tool geometry such as (rake angle and cutting edge radius) on the temperature distribution and residual stresses in machining surface of AISI 316L stainless steel have been presented. To evaluate the experimental results, various experimental equipment was used, such as a conventional lathe to carry out the machining operations, the cutting force was measured using a Kistler dynamometer and X-ray diffraction technique was employed for determination of the residual stresses distribution on the machined surfaces. In addition, A thermo-mechanically coupled finite element (FE) analysis for cutting process is developed through ABAQUS code to predict the temperature distribution and residual stresses using an Arbitrary Lagrangian-Eulerian (ALE) approach. An inverse identification method has been used to determine the adequate Johnson-Cook (JC) material model parameters to obtain a good correlation between the cutting force measurements and numerical one. The FE model was then validated by comparison of the numerical results of residual stresses with experimental measurements for different tool geometries, which revealed a reasonable agreement.

scholarly journals Prediction of Cutting Force and Chip Formation from the True Stress–Strain Relation Using an Explicit FEM for Polymer Machining

Polymers ◽  
2022 ◽  
Vol 14 (1) ◽  
pp. 189
Author(s):  
Bin Yang ◽  
Hongjian Wang ◽  
Kunkun Fu ◽  
Chonglei Wang
Keyword(s):  
Fracture Toughness ◽  
Friction Coefficient ◽  
Cutting Force ◽  
Failure Criterion ◽  
Chip Formation ◽  
Cutting Forces ◽  
Strain Curve ◽  
True Stress ◽  
Fe Model ◽  
Stress Strain

In the present work, an explicit finite element (FE) model was developed for predicting cutting forces and chip morphologies of polymers from the true stress–strain curve. A dual fracture process was used to simulate the cutting chip formation, incorporating both the shear damage failure criterion and the yield failure criterion, and considering the strain rate effect based on the Johnson–Cook formulation. The frictional behaviour between the cutting tool and specimen was defined by Coulomb’s law. Further, the estimated cutting forces and chip thicknesses at different nominal cutting depths were utilized to determine the fracture toughness of the polymer, using an existing mechanics method. It was found that the fracture toughness, cutting forces, and chip morphologies predicted by the FE model were consistent with the experimental results, which proved that the present FE model could effectively reflect the cutting process. In addition, a parametrical analysis was performed to investigate the effects of cutting depth, rake angle, and friction coefficient on the cutting force and chip formation, which found that, among these parameters, the friction coefficient had the greatest effect on cutting force.

Surface contour error model of five-axis machining considering multifactor coupling effects

2021 ◽  
pp. 095440622110058
Author(s):  
Shuyi Ge ◽  
Liping Wang ◽  
Guang Yu
Keyword(s):  
Cutting Force ◽  
Calculation Method ◽  
Flank Milling ◽  
Contour Error ◽  
Fe Model ◽  
Surface Contour ◽  
Cantilever Structure ◽  
Multifactor Coupling ◽  
Five Axis ◽  
The Impact

During five-axis flank milling procedure, the static deflection of workpiece and cutter creates surface errors that lead to defects in projects with strict requirements, especially in thin-walled parts industry. Focusing on the mentioned issues, the surface contour error is predicted in this paper considering the coupling between the deflection and cutting force. First, an efficient calculation method of the cutting force is presented in five-axis flank milling. This method accounts for the impact of cutter runout on cutter/workpiece engagement (CWE) and the instantaneous undeformed chip thickness (IUCT). Then, a cutter is modelled as a cantilever structure and thus an analytical solution for the deflection of the end mill can be obtained. Next, the flexible cutting force is distributed on a finite element (FE) model of workpiece, while the workpiece stiffness keeps varying with the material removal. Subsequently, a flexible iterative calculation method for achieving deflection prediction is established. Finally, the prediction model is proven by machining tests of an S-shaped specimen in which predicted values of the surface error match with the experimental results.

Machining FEM Model of Unidirectional Carbon Fiber Reinforced Laminate

2012 ◽  
Vol 601 ◽  
pp. 105-109
Author(s):  
Jing Yi Wang ◽  
Yan Li He ◽  
Xu Wang
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Chip Formation ◽  
Orthogonal Cutting ◽  
Surface Damage ◽  
Cutting Process ◽  
Fe Model ◽  
Cfrp Laminate ◽  
Finite Element Software ◽  
Chip Formation Mechanism

A two-dimensional macro-mechanical finite element (FE) model is developed to study the orthogonal cutting process of CFRP unidirectional laminate by the finite element software ABAQUS. The CFRP laminate is defined as an equivalent orthotropic, homogeneous single-phase material. On the basis of composite unidirectional laminate plane stress-strain and strength theory, the author adopts Hashin progressive damage criteria in the FE model. Based on the results of finite element simulation, the changes of cutting force in the chip formation process of CFRP laminate are analyzed, the Hashin damage in the cutting process and the influences of fiber orientation on cutting force, chip formation mechanism and sub-surface damage are explored as well. The comparison between this paper and previous related research shows that the results have a reasonable agreement with the previous achievements.

Nature instigated Grey wolf algorithm for parametric optimization during machining (Milling) of polymer nanocomposites

2021 ◽  
pp. 089270572199320
Author(s):  
Prakhar Kumar Kharwar ◽  
Rajesh Kumar Verma
Keyword(s):  
Surface Roughness ◽  
Cutting Force ◽  
Polymer Nanocomposites ◽  
Feed Rate ◽  
Fitness Function ◽  
Depth Of Cut ◽  
Multiwall Carbon Nanotube ◽  
Grey Wolf ◽  
Milling Characteristics ◽  
The Impact

The new era of engineering society focuses on the utilization of the potential advantage of carbon nanomaterials. The machinability facets of nanocarbon materials are passing through an initial stage. This article emphasizes the machinability evaluation and optimization of Milling performances, namely Surface roughness (Ra), Cutting force (Fc), and Material removal rate (MRR) using a recently developed Grey wolf optimization algorithm (GWOA). The Taguchi theory-based L27 orthogonal array (OA) was employed for the Machining (Milling) of polymer nanocomposites reinforced by Multiwall carbon nanotube (MWCNT). The second-order polynomial equation was intended for the analysis of the model. These mathematical models were used as a fitness function in the GWOA to predict machining performances. The ANOVA outcomes efficiently explore the impact of machine parameters on Milling characteristics. The optimal combination for lower surface roughness value is 1.5 MWCNT wt.%, 1500 rpm of spindle speed, 50 mm/min of feed rate, and 3 mm depth of cut. For lower cutting force, 1.0 wt.%, 1500 rpm, 90 mm/min feed rate and 1 mm depth of cut and the maximize MRR was acquired at 0.5 wt.%, 500 rpm, 150 mm/min feed rate and 3 mm depth of cut. The deviation of the predicted value from the experimental value of Ra, Fc, and MRR are found as 2.5, 6.5 and 5.9%, respectively. The convergence plot of all Milling characteristics suggests the application potential of the GWO algorithm for quality improvement in a manufacturing environment.

Experimental Examination of the Impact of Tool Radius on Specific Energy in Microcutting of Granite

2017 ◽  
Vol 139 (4) ◽  
Author(s):  
Miloš Pjević ◽  
Ljubodrag Tanović ◽  
Goran Mladenović ◽  
Biljana Marković
Keyword(s):  
Cutting Force ◽  
Penetration Depth ◽  
Specific Energy ◽  
Brittle Materials ◽  
Experimental Examination ◽  
Workpiece Surface ◽  
Different Shapes ◽  
Tip Radius ◽  
The Impact ◽  
Force Intensity

The paper presents experimental results of microcutting brittle materials (granite). The analysis was conceived on the observed interaction between the workpiece and two tools of different shapes. Experiment was based on scratching the workpiece surface with diamond tools. Applied tools had tip radius R0.2 and R0.15 mm. The experiment determined the changes in the value of perpendicular and tangential components of the cutting force based on the geometric properties of tools, as well as the changes of the specific energy of microcutting granite (Jošanica and Bukovik types). The experiment has shown that reduction of tool radius causes reduction of the cutting force intensity and specific cutting energy. Because of its physical/mechanical properties, more energy is required for micromachining granite “Jošanica” than “Bukovik.” Based on the topography of the surface, the value of critical tool penetration depth was established, after which the brittle fracture is no longer present. For granite “Jošanica” values of critical penetration depth are 6 and 5 μm when micromachining with tools R0.2 and R0.15 mm, while for Bukovik those values are 6.5 and 5.5 μm. The paper should form the basis for understanding the phenomena which occur during microcutting brittle materials.

Molecular Dynamics Study on the Impact of the Cutting Depth to the Titanium Nanometric Cutting

2014 ◽  
Vol 536-537 ◽  
pp. 1431-1434 ◽  
Author(s):  
Ying Zhu ◽  
Yin Cheng Zhang ◽  
Shun He Qi ◽  
Zhi Xiang
Keyword(s):  
Molecular Dynamics ◽  
Potential Energy ◽  
Cutting Force ◽  
Simulation Study ◽  
Cutting Process ◽  
Work Piece ◽  
Cutting Depth ◽  
Nanometric Cutting ◽  
The Impact

Based on the molecular dynamics (MD) theory, in this article, we made a simulation study on titanium nanometric cutting process at different cutting depths, and analyzed the changes of the cutting depth to the effects on the work piece morphology, system potential energy, cutting force and work piece temperature in this titanium nanometric cutting process. The results show that with the increase of the cutting depth, system potential energy, cutting force and work piece temperature will increase correspondingly while the surface quality of machined work piece will decrease.

Tribological characteristics of AA8090-WC-ZrC metal matrix composites prepared by stir casting process for Aerospace applications

2021 ◽  
Vol 73 (6) ◽  
pp. 980-985
Author(s):  
Kalaiyarasan A ◽  
Sundaram S ◽  
Gunasekaran K ◽  
Bensam Raj J.
Keyword(s):  
Metal Matrix ◽  
Materials Science ◽  
Scientific Information ◽  
High Hardness ◽  
Hardness Test ◽  
Casting Process ◽  
Stir Casting ◽  
Hybrid Particles ◽  
Content Type ◽  
The Impact

Purpose Aerospace field is demanding a material with superior strength and high resistance against wear, tear and corrosion. The current study aimed to develop a new material with high performance to be applicable in aerospace field Design/methodology/approach A metal matrix composite AA8090-WC-ZrC was fabricated using stir casting method and its tribological behavior was investigated. Totally, five composites viz. AA/Z, AA/W, AA/WZ (1:3), AA/WZ (1:1) & AA/WZ (3:1) were prepared. Micro hardness, tensile and wear study were performed on the fabricated composites and the results were compared with AA8090 alloy Findings Vickers hardness test resulted that the AA/W composite showed the higher hardness value of 160 HB compared to other materials due to the reinforcing effect of WC particles with high hardness. Tensile test reported that the AA/W composite displayed the maximum tensile strength of 502 MPa owing to the creation of more dislocation density. Further, wear study showed that the AA/W composite exhibited the least wear rate of 0.0011 mm3/m because of the more resisting force offered by the WC particles. Furthermore, the AA/W composite showed the slightest mass loss of 0.0028 g and lower COF value of 0.31 due to the hinder effect of WC particle to the movement of atoms in AA8090 alloy Originality/value This work is original in the field of aerospace engineering and materials science which deals with the fabrication of AA8090 alloy with the reinforcement particles such as tungsten carbide and zirconium carbide. The impact of the combination of hybrid particles and their volume fractions on the tribological properties has been investigated in this work. This work would provide new scientific information to society.

Fractality of Simulated Fracture

2009 ◽  
Vol 409 ◽  
pp. 154-160 ◽  
Author(s):  
Petr Frantík ◽  
Zbyněk Keršner ◽  
Václav Veselý ◽  
Ladislav Řoutil
Keyword(s):  
Numerical Model ◽  
Elastic Plate ◽  
Model Simulation ◽  
Element Model ◽  
The Other ◽  
Particle Model ◽  
Discrete Element Model ◽  
Fractal Nature ◽  
Discrete Elements ◽  
The Impact

The paper is focussed on numerical simulations of the fracture of a quasi-brittle specimen due to its impact onto a fixed rigid elastic plate. The failure of the specimen after the impact is modelled in two ways based on the physical discretization of continuum: via physical discrete elements and pseudo-particles. Advantages and drawbacks of both used methods are discussed. The size distribution of the fragments of the broken specimen resulting from physical discrete element model simulation follows a power law, which indicates the ability of the numerical model to identify the fractal nature of the fracture. The pseudo-particle model, on the other side, can successfully predict the kinematics of the fragments of the specimen under impact failure.

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