A study investigating the cutting mechanism of compacted graphite iron based on a novel microstructure of finite element model

Meng, Fanning; Zhang, Zhenyu; Feng, Jiajian; Gu, Qinming; Wu, Bin; Wang, Jianmei

doi:10.1016/j.jmapro.2022.06.065

Cited by 8 publications

(4 citation statements)

References 24 publications

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“…Increasing nose radius increases cutting temperature depending mainly on cutting speed reaching a maximum of 21% at higher cutting speeds. 4 Considerably increasing the feed rate increases the average surface roughness to about 120% at high cutting speeds and a large nose radius. On the other hand, increasing cutting speed and nose radius reduce the surface roughness by a maximum of 29 and 23%, respectively.…”

Section: Discussionmentioning

confidence: 99%

“…Furthermore, higher feed rates increased the cutting force components, whereas it slightly reduced the average cutting temperature after it was initially increased. Meng et al [4] applied a novel method in simulation to establish a microstructural model while investigating the machinability of graphite iron. The chip and cut surface morphologies, their formation mechanisms, and cutting temperature distribution were studied through the application of MATLAB image recognition and Python programming.…”

Section: Introductionmentioning

confidence: 99%

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Investigation and Statistical Analysis for Optimizing Surface Roughness, Cutting Forces, Temperature, and Productivity in Turning Grey Cast Iron

Rayes

Abbas

Al-Abduljabbar

et al. 2023

Metals

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This paper investigated the influence of cutting parameters, including feed rate, cutting speed, tool nose radius, and wet or dry cutting conditions, on the resultant force, cutting edge/workpiece temperature, and surface roughness when turning grey cast iron. Results showed that increasing the feed rate increased the resultant force, cutting temperature, and surface roughness. At the same time, increasing the cutting speed and nose radius increased the cutting temperature, which in turn reduced the resultant force. For practical applications, basic mathematical calculations based on the sole effect of each parameter on the output of the experiments were used to estimate the extent of percentage increase in cutting temperature due to increasing feed rate, cutting speed, and nose radius. Similarly, the same approach was used to estimate the effect of increasing feed rate, cutting speed, and nose radius on average surface roughness. Results showed that increasing the feed rate increases the cutting temperature by 5 to 11% depending on the nose radius and cutting speed. On the other hand, increasing the cutting speed was found to have limited effect on cutting temperature with small nose radius whereas this effect increases with increasing the nose radius reaching about 11%. Increasing the nose radius also increases the cutting temperature, depending mainly on cutting speed, reaching a maximum of 21% at higher cutting speeds. Results also showed that increasing the feed rate increased the average surface roughness considerably to about 120% at high cutting speeds and a large nose radius. On the other hand, increasing the cutting speed and nose radius reduced the surface roughness (i.e., improved surface quality) by a maximum of 29 and 23%, respectively. In order to study the combined effects of the cutting parameters on the three responses, namely, the resultant cutting force, cutting temperature, and surface roughness, full factorial design and ANOVA were used, where it was found to be in good agreement with mathematical calculations. Additionally, the desirability function optimization tool was used to minimize the measured responses whilst maximizing the material removal rate.

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Section: Discussionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Investigation and Statistical Analysis for Optimizing Surface Roughness, Cutting Forces, Temperature, and Productivity in Turning Grey Cast Iron

Rayes

Abbas

Al-Abduljabbar

et al. 2023

Metals

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show abstract

“…In this paper, the cutting processes of graphite were simulated using the finite element analysis software ABAQUS 2021/Explicit, which is widely used to solve short-term, transient dynamic problems such as high-speed cutting, impacts, and explosions [24,29,30]. As shown in Figure 1, the cutting thickness is a c , and the material fails and forms chips during the cutting process.…”

Section: Finite Element Modellingmentioning

confidence: 99%

“…Ma et al [23] established a theoretical model of the characteristic temperature of fluorophlogopite ceramics based on the law of conservation of energy and the principle of fracture mechanics, and studied the continuous fracture mechanism of the materials. Meng et al [24] analysed the chip morphology and cutting mechanism during the machining of compacted graphite iron by finite element modelling. However, finite element modelling capable of simulating the entire cutting and machining process of graphite materials was not reported.…”

Section: Introductionmentioning

confidence: 99%

Finite Element Modelling and Experimental Validation of the Graphite Cutting Process

Yang,

Wei,

Wang

et al. 2023

Processes

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Graphite is extensively used in the engineering field due to its unique properties, and the study of its cutting mechanism has become particularly important. However, the brittle fracture mechanism of graphite makes it rather easy for cracks with a unique pattern of initiation and growth to develop when processing. Herein, the ABAQUS was selected to establish a finite element model (FEM) of the graphite cutting process. The internal crystal structure of graphite was modelled by a Voronoi structure, and a cohesion unit was globally embedded into the solid unit to simulate crack initiation and growth. In addition, the complete process of chip formation and removal was demonstrated. The analysis of the simulation results showed that the graphite material underwent three periodic cycles of material removal during the cutting process, i.e., large, tiny, and small removal stages. Meanwhile, the simulation results indicated that when ac was large enough, the crack gradually grew inside the graphite and then turned to the upper surface of the graphite. However, when ac was tiny enough, the cracks hardly expanded towards the inside of the graphite but grew upwards for a short period. Then, orthogonal cutting experiments of graphite were conducted, and the FEM was verified based on the experimental chip morphology, machined surface morphology, and current geometric model of the graphite cutting process. The simulation and experimental results were consistent. The hereby-presented FEM was a complement to simulations of the processing of brittle materials.

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Plastic deformation mechanism of grinding subsurface of nickel-based single-crystal superalloy

Cai,

Gong,

Gao

et al. 2023

Int J Adv Manuf Technol

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A study investigating the cutting mechanism of compacted graphite iron based on a novel microstructure of finite element model

Cited by 8 publications

References 24 publications

Investigation and Statistical Analysis for Optimizing Surface Roughness, Cutting Forces, Temperature, and Productivity in Turning Grey Cast Iron

Investigation and Statistical Analysis for Optimizing Surface Roughness, Cutting Forces, Temperature, and Productivity in Turning Grey Cast Iron

Finite Element Modelling and Experimental Validation of the Graphite Cutting Process

Plastic deformation mechanism of grinding subsurface of nickel-based single-crystal superalloy

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