Approaches for modelling and simulation of metal machining – a critical review

Leopold, Jürgen

doi:10.1051/mfreview/2014005

Cited by 3 publications

(2 citation statements)

References 51 publications

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“…Authors like Özel et al [3], Leopold [14], and Chinchanikar et al [15] developed finite element studies for the orthogonal cutting in HSM. Continuous re-meshing and adaptive meshing are the principal tools employed for avoiding the difficulties associated with deformation-induced element distortion, and for resolving fine-scale features in the solution.…”

Section: Figmentioning

confidence: 99%

Finite Element Modeling of Temperature Fields on the Cutting Edge in the Dry High-Speed Turning of Aisi 1045 Steel

et al. 2020

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High-speed turning is an advanced and emerging machining technique that, in contrast to the conventional machining, allows the manufacture of the workpiece with high accuracy, efficiency and quality, with lower production costs and with a considerable reduction in the machining times. The cutting tools used for the conventional machining cannot be employed for high-speed machining due to a high temperature induced in machining and a lower tool life. Therefore, it is necessary to study the influence of high cutting speeds on the temperature distribution in different typologies of cutting tools, with the aim of evaluating their behavior. In this paper, a finite element method modeling approach with arbitrary Lagrangian-Eulerian fully coupled thermal-stress analysis is employed. The research presents the results of different cutting tools (two coated carbide tools and uncoated cermet) effects on average surface temperature fields on the cutting edge in the dry high-speed turning of AISI 1045 steel. The numerical experiments were designed based on different cutting tools like input parameters and different temperature field zones like dependent variables in the dry high-speed turning of AISI 1045 steel. The results indicate that the dry high-speed turning of AISI 1045 steel does not influence significantly the temperature field zones when P10, P15 or P25 inserts are used. Therefore, the use of a dry high-speed turning method, which reduces the amount of lubricant and increases productivity, may represent an alternative to turning to the extent here described.

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Section: Figmentioning

confidence: 99%

Finite Element Modeling of Temperature Fields on the Cutting Edge in the Dry High-Speed Turning of Aisi 1045 Steel

et al. 2020

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“…The small length and time scales of micro- and nanocutting processes when compared to their macroscale counterparts makes them suitable systems for molecular dynamic (MD) simulations, allowing for the study of the physical and chemical mechanisms to occur at the tool/workpiece interface at the atomistic level. While other simulation approaches, such as finite element simulations [ 21 ], allow for a large-scale simulation of the cutting process, MD allows for the tracking of forces, stresses, and temperature at the atomistic level, as well as the microscopic deformations of the tool/workpiece pair and, if a suitable forcefield is used, the tribochemical reactions at the interface. Therefore, MD simulations are now regarded as one of the key methods in understanding micro-and nanomachining, as testified by various comprehensive accounts [ 22 , 23 , 24 ].…”

Section: Introductionmentioning

confidence: 99%

Molecular Dynamics Simulation of Ti Metal Cutting Using a TiN:Ag Self-Lubricating Coated Tool

Lenzi

Marques

2023

Materials

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Silver-ceramic nanocomposite coatings, such as TiN:Ag, are among the most interesting solutions to improve the machining and cutting process of hard-to-cut Ti alloys, since they combine the TiN matrix hardness with the lubricating and protective action of Ag nanoparticles. Therefore, it is important to understand how, when present, Ag distributes at the tool-workpiece interface and how it affects the tribolayer formation and the tool wear. Molecular dynamics simulation results, obtained using a MEAM-based force field, are presented here for the cutting process of a Ti workpiece with a TiN tool, with and without the presence of Ag at the interface, for different cutting speeds. Ag is shown to form a thin protective layer at the workpiece-tool interface that prevents a direct contact between the parts and greatly reduces the tool degradation. Our simulations confirm the importance of Ag in self-lubricating nanocomposite coatings to realize the machining of otherwise hard-to-cut materials.

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Cutting Simulations Using a Commercially Available 2D/3D FEM Software for Forming

et al. 2017

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Approaches for modelling and simulation of metal machining – a critical review

Cited by 3 publications

References 51 publications

Finite Element Modeling of Temperature Fields on the Cutting Edge in the Dry High-Speed Turning of Aisi 1045 Steel

Finite Element Modeling of Temperature Fields on the Cutting Edge in the Dry High-Speed Turning of Aisi 1045 Steel

Molecular Dynamics Simulation of Ti Metal Cutting Using a TiN:Ag Self-Lubricating Coated Tool

Cutting Simulations Using a Commercially Available 2D/3D FEM Software for Forming

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