A new damage evolution criterion for the coupled Eulerian-Lagrangian approach: Application to three-dimensional numerical simulation of segmented chip formation mechanisms in orthogonal cutting

Ambrosio, Danilo; Tongne, Amèvi; Wagner, Vincent; Dessein, Gilles; Cahuc, Olivier

doi:10.1016/j.jmapro.2021.10.062

Cited by 18 publications

(3 citation statements)

References 29 publications

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“…Das et al [229] develop a finite element model using the coupled Eulerian-Lagrangian (CEL) approach for interpreting the tool-material interaction and predicting both the volumetric defect and the surface texture with optimum condition of mass scaling. Several solid mechanics approaches, such as the Eulerian or Lagrangian approach, smoother particle hydrodynamics (SPH), coupled Eulerian and Lagrangian (CEL), and arbitrary Lagrangian and Eulerian (ALE) [230] techniques, can be employed to model the thermo-mechanical behavior of the friction stir welding (FSW) process [231][232][233]. The CEL approach is suitable for the modelling of the dissimilar FSW process [234].…”

mentioning

confidence: 99%

Effect of Process Parameters on Friction Stir Welded Joints between Dissimilar Aluminum Alloys: A Review

Bella

Favaloro

Borsellino

2023

Metals

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Friction Stir Welding is a suitable solid-state joining technology to connect dissimilar materials. To produce an effective joint, a phase of optimization is required which leads to the definition of process parameters such as pin geometry, tool rotational speed, rotation direction, welding speed, thickness of the sheets or tool tilt angle. The aim of this review is to present a complete and detailed frame of the main process parameters and their effect on the final performance of a friction stir welded joint in terms of mechanical properties and microstructure. Attention was focused in particular on the connection between different aluminum alloys. Moreover, the experimental results were correlated to the development and the applications of tools which can be effectively used in the design of the manufacturing process such as finite element analyses, artificial neural networks, and statistical studies. The review also aims to be a point of reference to identify the best combinations of process parameters based on the dissimilar aluminum to be joined.

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mentioning

confidence: 99%

Effect of Process Parameters on Friction Stir Welded Joints between Dissimilar Aluminum Alloys: A Review

Bella

Favaloro

Borsellino

2023

Metals

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“…Accurate FEA simulations consider cutting parameters, material models, and heat generation to optimise machining processes. During heat generation, a friction model [102] should accurately simulate the interactions between the tool and workpiece during machining. These thermodynamic considerations are critical assessments for carrying out the machining simulation.…”

Section: Assembly Numerical Modellingmentioning

confidence: 99%

INCONEL® Alloy Machining and Tool Wear Finite Element Analysis Assessment: An Extended Review

Pedroso,

Sebbe,

Costa

et al. 2024

JMMP

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Machining INCONEL® presents significant challenges in predicting its behaviour, and a comprehensive experimental assessment of its machinability is costly and unsustainable. Design of Experiments (DOE) can be conducted non-destructively through Finite Element Analysis (FEA). However, it is crucial to ascertain whether numerical and constitutive models can accurately predict INCONEL® machining. Therefore, a comprehensive review of FEA machining strategies is presented to systematically summarise and analyse the advancements in INCONEL® milling, turning, and drilling simulations through FEA from 2013 to 2023. Additionally, non-conventional manufacturing simulations are addressed. This review highlights the most recent modelling digital solutions, prospects, and limitations that researchers have proposed when tackling INCONEL® FEA machining. The genesis of this paper is owed to articles and books from diverse sources. Conducting simulations of INCONEL® machining through FEA can significantly enhance experimental analyses with the proper choice of damage and failure criteria. This approach not only enables a more precise calibration of parameters but also improves temperature (T) prediction during the machining process, accurate Tool Wear (TW) quantity and typology forecasts, and accurate surface quality assessment by evaluating Surface Roughness (SR) and the surface stress state. Additionally, it aids in making informed choices regarding the potential use of tool coatings.

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“…Recently, in order to overcome the drawbacks of the ALE formulation during the simulations, a so-called Coupled Eulerian-Lagrangian formulation (CEL) has been developed for the simulation of orthogonal cutting. [19][20][21][22][23] Initially, the CEL formulation was only used to study fluid-structure interactions. Currently, this approach is being adopted to simulate the cutting process and is becoming a promising alternative.…”

Section: Introductionmentioning

confidence: 99%

Comparison of the CEL and ALE approaches for the simulation of orthogonal cutting of 15-5PH and 42CrMo4 materials

Aridhi

Perard

Valiorgue

et al. 2022

Proceedings of the Institution of Mechanical Engineers, Part B:

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The modeling of cutting processes by the finite element method represents a great challenge for scientific researchers. Indeed, the plastic strain and strain rate in cutting induce a high risk of mesh distortion, especially for models based on a Lagrangian formulation which were the first to be developed. To overcome this problem other formulations, such as the Arbitrary Eulerian-Lagrangian (ALE), which is a combination of the classical formulations (Eulerian and Lagrangian), have been developed. Despite very interesting results in the simulation of orthogonal cutting, the implementation of this type of model remains delicate, and in particular the choice of initial geometrical conditions which can lead to a sudden stop of the calculation induced by a mesh distortion. To overcome these limitations, the Coupled Eulerian-Lagrangian (CEL) approach has been developed to simulate the orthogonal cutting process. In this paper, the CEL and ALE approaches were compared to simulate the orthogonal cutting process. The first objective was to compare the quality of the predicted physical quantities (forces, chips) over a wide range of cutting speeds and cutting thicknesses for two different materials. The second objective was to evaluate the time required for a complete simulation, integrating the time to set up the initial conditions (chip geometry) and finally the computation time of the machining operation. This work has shown that ALE and CEL formulations lead to very similar quantitative results that are pretty close to the experimental results. The ALE formulation has the advantage of having a reduced computation time compared to the CEL formulation. However, the preparation of the simulation is easy and robust for the CEL, whereas the selection of initial geometrical conditions for the ALE calculation requires several trials and errors before finding stable conditions. The CEL formulation is therefore a solution to be favored when launching several simulations in an automated way thanks to its reliability.

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A new damage evolution criterion for the coupled Eulerian-Lagrangian approach: Application to three-dimensional numerical simulation of segmented chip formation mechanisms in orthogonal cutting

Cited by 18 publications

References 29 publications

Effect of Process Parameters on Friction Stir Welded Joints between Dissimilar Aluminum Alloys: A Review

Effect of Process Parameters on Friction Stir Welded Joints between Dissimilar Aluminum Alloys: A Review

INCONEL® Alloy Machining and Tool Wear Finite Element Analysis Assessment: An Extended Review

Comparison of the CEL and ALE approaches for the simulation of orthogonal cutting of 15-5PH and 42CrMo4 materials

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