Chip formation during microscale cutting of a medium carbon steel

Simoneau, A.; Ng, Eugene; Elbestawi, M.A.

doi:10.1016/j.ijmachtools.2005.07.019

Cited by 124 publications

(77 citation statements)

References 38 publications

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“…Application of FE simulation to the cutting process provides an effective means to understand the mechanics and characteristics of the cutting process. It has been used successfully for the prediction of cutting forces, temperature distribution and stress distribution, etc, with a practical accuracy at the macro level [2][3][4][5]. However, FE method can not be used for the simulation of nanometric cutting because the constitutive equations have vital errors when the mesh size approaches to the atomic scale.…”

Section: Introductionmentioning

confidence: 99%

Multi-scale simulation of the nano-metric cutting process

Sun

Cheng

2009

Int J Adv Manuf Technol

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Molecular dynamics (MD) simulation and finite element (FE) method are two popular numerical techniques for the simulation of machining processes. The two methods have their own strengths and limitations. The MD simulation can cover the phenomena occurring at nanometric scale lengths but limited by the computational cost and capacity, while FE method is suitable for modelling the meso to macro scale machining and for simulating macro parameters such as the temperature in a cutting zone, the stress/strain distribution and cutting forces, etc. With the successful application of multiscale simulations in many research fields, the application to simulate machining processes is emerging particularly in relation to the machined surface generation and integrity formation, i.e. the machined surface roughness, residual stress, microhardness, microstructure and fatigue.Based on the Quasicontinuum (QC) method, the multiscale simulation of nanometric cutting has been proposed. Cutting simulations are performed on single crystal aluminium to investigate the chip formation, generation and propagation of the material dislocation during the cutting process. In addition, the effect of the tool rake angle on cutting force and internal stress under the workpiece surface is investigated. The cutting force and internal stress in the workpiece material decrease with the increase of the rake angle. Finally, to ease and speed up multiscale modelling and simulation steps, a computing efficient MATLAB-based program has been developed, which facilitates the geometrical cutting modelling, simulation conditions, implementation of simulation and results analysis within a unified integrated virtual simulation environment.

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Section: Introductionmentioning

confidence: 99%

Multi-scale simulation of the nano-metric cutting process

Sun

Cheng

2009

Int J Adv Manuf Technol

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“…However, further increase in the cutting speed to 180 m/min causes increase in the chip thickness ratio. It is observed from their work that at lower and medium cutting speed of 60 m/min and 120 m/min respectively, the chip thickness ratio follows the decreasing trend, which agrees to the fundamentals of metal cutting [13]. Simoneau et al [14] concluded that microstructure has a significant effect on micro-scale cutting.…”

Section: Introductionmentioning

confidence: 52%

“…A good agreement was found between the predicted shear angle in machining a polycrystalline OFHC copper and the experimental data reported. Pawade et al [13] observed that as the cutting speed increases from 60 m/min to 120 m/min, the chip thickness ratio decreases by small value. However, further increase in the cutting speed to 180 m/min causes increase in the chip thickness ratio.…”

Section: Introductionmentioning

confidence: 99%

Experimental analysis of orthogonal micro-machined surface features and chip morphology of AISI1215 steel by using EBSD method

Yadav

Waikar

Pawade

et al. 2017

Proceedings of the International Conference on Communication and Signal Processing 2016 (ICCASP 2016)

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Abstract:In this work analysis of fundamental aspects of orthogonal microcutting was carried out in terms of variables like shear angle, chip thickness, chip morphology as a function of cutting speed, depth of cut, tool rake angle and heat treatment provided to the work specimen. Analysis of results shows that the material flow pattern at low cutting speed is highly inhomogeneous, which affects segmented chip formation. As the uncut chip thickness approaches the minimum chip thickness, chips are formed by shearing of the workpiece, with some elastic deformation still occurring.At the highest depth of cut of 100 µm, shear angle is fairly dependent on the rake angle. AISI 1215 steel heat treated at 1200C, shows the lowest shear angle at all the depths of cut at 5 or 10 of rake angle. Analyses of chip segment per unit length show that, the number of segments reduces as the rake angle increases for all the four work materials that were heat treated at the various temperatures.

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“…[15][16][17] for example). Also in general, cutting speeds attained in microcutting are significantly lower than those usually achieved in macro-cutting.…”

Section: Introductionmentioning

confidence: 99%

Development of a precision machine to perform and study orthogonal micro-cutting

Fromentin

Gasparoux

Agbeviade

et al. 2016

Prod. Eng. Res. Devel.

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This article presents a laboratory machine designed to perform orthogonal micro-cutting experiments. The machine allows an accurate control of the various cutting parameters and a direct comparison of micro-and macrocutting tool-material data bases. Research with the machine will focus on validating the application of macrocutting data to at least a range of microcutting applications and to define the limits beyond which such applications are no longer possible. The paper describes the machine and its design specifications and provides the validation of the performances claimed. The machine can cut in a reproducible manner with depths of cut as low as 1 lm, at speeds in the range 50-1000 mm/s, while measuring the cutting and thrust forces. The variability in nominal depth of cut is equal or better than 1 lm. Application examples illustrate the influence of lubrication and lead additions on the cutting process and demonstrate that the machine is indeed suitable for the application for which it was designed.

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Chip formation during microscale cutting of a medium carbon steel

Cited by 124 publications

References 38 publications

Multi-scale simulation of the nano-metric cutting process

Multi-scale simulation of the nano-metric cutting process

Experimental analysis of orthogonal micro-machined surface features and chip morphology of AISI1215 steel by using EBSD method

Development of a precision machine to perform and study orthogonal micro-cutting

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