Investigation of the Impact Analysis of Microscale Thin-Walled Structures Manufactured by High-Speed Machining

2006 ◽  
pp. 1599-1602
Author(s):  
Bo Sung Shin
Keyword(s):  
High Speed ◽  
Impact Analysis ◽  
High Speed Machining ◽  
Thin Walled Structures ◽  
Thin Walled ◽  
The Impact

Investigation of the Impact Analysis of Microscale Thin-Walled Structures Manufactured by High-Speed Machining

2006 ◽  
Vol 326-328 ◽  
pp. 1599-1602
Author(s):  
Bo Sung Shin
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
High Speed ◽  
Impact Analysis ◽  
Thin Wall ◽  
High Speed Machining ◽  
High Speed Cutting ◽  
Thin Walled Structures ◽  
Thin Walled ◽  
The Impact

High-speed machining (HSM) is very useful method as one of the most effective manufacturing processes because it has excellent quality and dimensional accuracy for precision machining. Recently micromachining technologies of various functional materials with very thin walls are needed in the field of electronics, mobile telecommunication and semiconductors. However, HSM is not suitable for microscale thin-walled structures because of the lack of their structure stiffness to resist high-speed cutting force. A microscale thin wall machined by HSM shows the characteristics of the impact behavior because the high-speed cutting force works very shortly on the machined surface. We propose impact analysis model in order to predict the limit thickness of a very thin-wall and investigate its limit thickness of thin-wall manufactured by HSM using finite element method. Also, in order to verify the usefulness of this method, we will compare finite element analyses with experimental results and demonstrate some applications.

Energy absorbed ability and damage analysis for honeycomb sandwich material of bio-inspired micro aerial vehicle under low velocity impact

2020 ◽  
pp. 095440622097542
Author(s):  
Jianxun Du ◽  
Peng Hao ◽  
Mabao Liu ◽  
Rui Xue ◽  
Lin’an Li
Keyword(s):  
Honeycomb Structure ◽  
Low Velocity Impact ◽  
Parameter Study ◽  
Low Velocity ◽  
Micro Aerial Vehicle ◽  
Thin Walled Structures ◽  
Wide Range ◽  
Aerial Vehicle ◽  
Thin Walled ◽  
The Impact

Because of the advantages of light weight, small size, and good maneuverability, the bio-inspired micro aerial vehicle has a wide range of application prospects and development potential in military and civil areas, and has become one of the research hotspots in the future aviation field. The beetle’s elytra possess high strength and provide the protection of the abdomen while being functional to guarantee its flight performance. In this study, the internal microstructure of beetle’s elytra was observed by scanning electron microscope (SEM), and a variety of bionic thin-walled structures were proposed and modelled. The energy absorption characteristics and protective performance of different configurations of thin-walled structures with hollow columns under impact loading was analyzed by finite element method. The parameter study was carried out to show the influence of the velocity of impactor, the impact angle of the impactor and the wall thickness of honeycomb structure. This study provides an important inspiration for the design of the protective structure of the micro aerial vehicle.

Experimental Calibration of ISV Damage Model Constants for Pure Copper for High-Speed Impact Simulation

2016 ◽  
Author(s):  
Yangqing Dou ◽  
Yucheng Liu ◽  
Wilburn Whittington ◽  
Jonathan Miller
Keyword(s):  
High Speed ◽  
Impact Analysis ◽  
Split Hopkinson Pressure Bar ◽  
Internal State ◽  
Pure Copper ◽  
Damage Model ◽  
Hopkinson Pressure Bar ◽  
Experimental Calibration ◽  
High Speed Impact ◽  
The Impact

Coefficients and constants of a microstructure-based internal state variable (ISV) plasticity damage model for pure copper have been calibrated and used for damage modeling and simulation. Experimental stress-strain curves obtained from Cu samples at different strain rate and temperature levels provide a benchmark for the calibration work. Instron quasi-static tester and split-Hopkinson pressure bar are used to obtain low-to-high strain rates. Calibration process and techniques are described in this paper. The calibrated material model is used for high-speed impact analysis to predict the impact properties of Cu. In the numerical impact scenario, a 100 mm by 100 mm Cu plate with a thickness of 10 mm will be penetrated by a 50 mm-long Ni rod with a diameter of 10mm. The thickness of 10 mm was selected for the Cu plate so that the Ni-Cu penetration through the thickness can be well observed through the simulations and the effects of the ductility of Cu on its plasticity deformation during the penetration can be displayed. Also, that thickness had been used by some researchers when investigating penetration mechanics of other materials. Therefore the penetration resistance of Cu can be compared to that of other metallic materials based on the simulation results obtained from this study. Through this study, the efficiency of this ISV model in simulating high-speed impact process is verified. Functions and roles of each of material constant in that model are also demonstrated.

scholarly journals Impact of Cutting Environments on Sustainable Machining of H13 Tool Steel Alloy

2020 ◽  
Vol 5 (2) ◽  
Author(s):  
Vincent A Balogun ◽  
Isuamfon F Edem ◽  
Etimbuk B Bassey
Keyword(s):  
Tool Life ◽  
Tool Steel ◽  
High Speed ◽  
Machining Process ◽  
Steel Alloy ◽  
High Speed Machining ◽  
Sustainable Machining ◽  
H13 Tool Steel ◽  
Green Machining ◽  
The Impact

The use of electrical energy and coolants/lubricants has been widely reported in mechanical machining. However, increased research and process innovation in high speed machining has brought about optimised manufacturing cycle times. This has promoted dry machining and the use of minimum quantity lubrication (MQL). This work understudies the impact of different cutting environments in machining H13 tool steel alloys at transition speed regime with emphasis on sustainable machining of the alloy. To achieve this, end milling tests were performed on AISI H13 steel alloy (192 BHN) on a MIKRON HSM 400 high speed machining centre using milling inserts. After each cutting pass, the milling insert was removed for tool wear measurement on the digital microscope. The electrical power consumed was measured with the Fluke 435 power clamp meter mounted on the three phase cable at the back of the machine. It was discovered that MQL has a promising advantage in terms of tool life with 25 minutes of machining, net power requirement of 10% when compared to dry cutting, and environmental benefits when machining H13 tool steel alloy. This work is fundamentally important in assessing the environmental credentials and resource efficiency regime for green machining of H13 tool steel alloysKeywords— H13 tool steel, green machining, process optimization, tool life, cutting environments, energy consumption 

scholarly journals Experimental and Numerical Impact Analysis of Automotive Bumper Brackets Made of 2D Triaxially Braided CFRP Composites

Materials ◽  
2020 ◽  
Vol 13 (16) ◽  
pp. 3554
Author(s):  
Robert Böhm ◽  
Andreas Hornig ◽  
Tony Weber ◽  
Bernd Grüber ◽  
Maik Gude
Keyword(s):  
High Speed ◽  
Impact Analysis ◽  
Damage Model ◽  
Drop Tower ◽  
Structural Deformation ◽  
Impact Behavior ◽  
Speed Test ◽  
Damage Models ◽  
The Impact ◽  
Carbon Fiber Epoxy

The impact behavior of carbon fiber epoxy bumper brackets reinforced with 2D biaxial and 2D triaxial braids was experimentally and numerically analyzed. For this purpose, a phenomenological damage model was modified and implemented as a user material in ABAQUS. It was hypothesized that all input parameters could be determined from a suitable high-speed test program. Therefore, novel impact test device was designed, developed and integrated into a drop tower. Drop tower tests with different impactor masses and impact velocities at different bumper bracket configurations were conducted to compare the numerically predicted deformation and damage behavior with experimental evidence. Good correlations between simulations and tests were found, both for the global structural deformation, including fracture, and local damage entities in the impact zone. It was proven that the developed phenomenological damage models can be fully applied for present-day industrial problems.

scholarly journals The Impact of 3D Printing Parameters on the Post-Buckling Behavior of Thin-Walled Structures

Materials ◽  
2020 ◽  
Vol 13 (21) ◽  
pp. 4742
Author(s):  
Tomasz Kopecki ◽  
Przemysław Mazurek ◽  
Łukasz Święch
Keyword(s):  
3D Printing ◽  
Numerical Solutions ◽  
Structure Mapping ◽  
Thin Walled Structures ◽  
Buckling Behavior ◽  
Post Buckling ◽  
Thin Walled ◽  
The Impact ◽  
Printing Direction ◽  
Bearing Structure

This study presents the results of experimental research and numerical calculations regarding models of a typical torsion box fragment, which is a common thin-walled load-bearing structure used in aviation technology. A fragment of this structure corresponding to the spar wall was made using 3D printing. The examined system was subjected to twisting and underwent post-critical deformation. The research was aimed at determining the influence of the printing direction of the structure’s individual layers on the system stiffness. The experimental phase was supplemented by nonlinear numerical analyses of the models of the studied systems, taking into account the details of the structure mapping using the laminate concept. The purpose of the calculations was to determine the usefulness of the adopted method for modeling the examined structures by assessing the compliance of numerical solutions with the results of the experiment.

Influences of Thermal Loads on Nonlinear Response of Thin-Walled Structures in Thermo-Acoustic Environment

2011 ◽  
Vol 105-107 ◽  
pp. 220-226 ◽  
Author(s):  
Yun Dong Sha ◽  
Zhi Jun Gao ◽  
Fei Xu
Keyword(s):  
High Speed ◽  
Nonlinear Response ◽  
Large Deflection ◽  
Thermal Protection ◽  
Thermal Loads ◽  
Acoustic Response ◽  
Restoring Force ◽  
Acoustic Environment ◽  
Thin Walled Structures ◽  
Thin Walled

Thin-walled structures of future hypersonic flight vehicles will encounter complex loadings and exhibit obvious nonlinear responses. The thermal loads from high speed flow or engine jet flow can cause thermal buckling of thin-walled structures, such as Thermal Protection System (TPS). If the structures are loaded with intense acoustic loads simultaneously, large deflection nonlinear response, including snap-through, can be induced. Snap-through will give rise to large amplitude stress cycles and non-zero mean stress, which can lessen the fatigue life markedly. Starting from Hooker’s Law with thermal components, the large deflection governing equations of motion for simply-supported plate under thermo-acoustic loadings are derived. The partial differential equation (PDE) of motion which is difficult to solve is then transformed with Galerkin’s method to the system of ordinary differential equations (ODE) under modal coordinates. The displacement responses under different combinations of temperature increments and sound pressure levels are calculated by employing Runge-Kutta method. Typical thermo-acoustic responses are predicted: 1) random vibration around pre-buckled equilibrium position, 2) persistent snap-through between post-buckled positions, 3) intermittent snap-through, 4) vibration around one of the two post-buckled positions. By dividing the restoring force term in the equation into linear term and nonlinear one, the evolutions of each term are obtained to illustrate the mechanism of thermo-acoustic response and the contributions of each force, including shear force, thermal force and membrane force. Thus a further insight into thermo-acoustic response has been achieved.

Impact Response of Thin-Walled Tubes: A Prospective Review

2012 ◽  
Vol 165 ◽  
pp. 130-134 ◽  
Author(s):  
Fauziah Mat ◽  
K. Azwan Ismail ◽  
S. Yaacob ◽  
O. Inayatullah
Keyword(s):  
Compressive Loading ◽  
Axial Loading ◽  
Geometrical Parameters ◽  
Axial Deformation ◽  
Thin Walled Structures ◽  
Structural Applications ◽  
Thin Walled ◽  
Energy Absorbers ◽  
Energy Absorbing ◽  
The Impact

Thin-walled structures have been widely used in various structural applications asimpact energy absorbing devices. During an impact situation, thin-walled tubesdemonstrate excellent capability in absorbing greater energy through plastic deformation. In this paper, a review of thin-walled tubes as collapsible energy absorbers is presented.As a mean of improving the impact energy absorption of thin-walled tubes, the influence of geometrical parameters such as length, diameter and wall thickness on the response of thin-walled tubes under compression axial loading are briefly discussed. Several design improvements proposed by previous researchers are also presented. The scope of this review is mainly focus on axial deformation under quasi-static and dynamic compressive loading. Other deformations, such as lateral indentation, inversion and splitting are considered beyond the scope of this paper. This review is intended to assist the future development of thin-walled tubes as efficient energy absorbing elements.

The Impact of High Speed Machining Technology on the Design and Fabrication of Aerospace Components

1999 ◽  
Author(s):  
J. E. Halley ◽  
A. M. Helvey ◽  
K. S. Smith ◽  
W. R. Winfough
Keyword(s):  
High Speed ◽  
High Speed Machining ◽  
End Mill ◽  
Military Aircraft ◽  
Thin Structures ◽  
Thin Structure ◽  
The Face ◽  
Basic Technology ◽  
The Impact ◽  
Solid Block

Abstract Recently, several new machining techniques have been developed which have driven dramatic changes in the manufacture of aerospace components with thin ribs and webs. There are many such components in commercial and military aircraft, and until recently these components we fabricated as sheet metal assemblies. Through an improved understanding of the dynamic interaction between the tool and workpiece, it has now become economically competitive to create components with thin ribs and webs as monolithic units machined from a solid block by milling. Ribs are those thin structures created at the periphery of the end mill, as opposed to webs, which are the thin structures created at the face of the end mill. It is easy to see that as the ribs and webs become thinner, the stiffnesses will decrease, and chatter will become more problematic. Chatter during the machining of such parts can result in damage to the part (even cutting through the thin structure) or at least poor surfaces which require hand finishing. This paper outlines the basic technology required to produce these kinds of components efficiently, and cites several examples.

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