Development of FEM-based digital twins for machining difficult-to-cut materials: A roadmap for sustainability

Carvalho, Sílvia; Lauro, Carlos Henrique; Ana, Horovistiz; Davim, J. Paulo

doi:10.1016/j.jmapro.2022.01.027

Cited by 15 publications

(4 citation statements)

References 112 publications

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“…It is a 5-axis system with a high-speed spindle, with a maximum speed of 18 × 10 3 rpm, a maximum spindle power of 21 kW, a table load of up to 300 kg and a large diameter of table bearings for highest precision. For more information, see [20][21][22].…”

Section: Milling Machinementioning

confidence: 99%

Stochastic Evaluation of Cutting Tool Load and Surface Quality during Milling of HPL

et al. 2022

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The topic of the article concerns the mechanics of machining plastics and their machined surface. This article deals with measurements and their stochastic (probabilistic) evaluation of the force and moment loading of the machine tools and workpiece. It also deals with the quality of the machined surface in relation to its surface roughness and surface integrity. Measurements were made under different cutting conditions on a CNC milling machine using a newly designed cutter with straight teeth. The statistical evaluation is presented by bounded histograms and basic statistical characteristics that give a realistic idea of the machining process. The practical focus of the experiments is on the milling of HPL (high-pressure plastic–laminate composite material). The listed procedures can also be applied to other materials and machining methods, and can be used for numerical modelling, setting the optimum parameters of machining technology, or for the design of cutting tools. Numerical modelling and other solution options are also mentioned. We have not yet found detailed information in the literature about the milling of HPL material, and our results are therefore new and necessary.

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Section: Milling Machinementioning

confidence: 99%

Stochastic Evaluation of Cutting Tool Load and Surface Quality during Milling of HPL

et al. 2022

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“…glass fiber-reinforced aluminum laminates and composite/metal stacks) [21][22][23][24]. The mechanical machining of difficult-to-cut materials and geometrically complex components is usually accompanied by high cutting force and temperature, rapid tool wear, low MRR, low machining accuracy, poor surface finish, and machining-induced defects [25][26][27][28][29]. These issues can further result in a reduced machining efficiency, inconsistent quality, increased energy consumption, and higher machining cost.…”

Section: Introductionmentioning

confidence: 99%

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Zhao,

Ding

et al. 2024

Int. J. Extrem. Manuf.

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Difficult-to-cut materials such as titanium alloys, high-temperature alloys, metal/ceramic/polymer-matrix composites, hard and brittle materials, as well as geometrically complex components such as thin-walled structures, micro channels and complex surfaces, are widely used in aerospace community. Mechanical machining is the main material removal process and responsible for the vast majority of material removal for aerospace components. Nevertheless, it encounters many problems in terms of severe and rapid tool wear, low machining efficiency, and deteriorated surface integrity. Nontraditional energy-assisted mechanical machining is a hybrid process in which nontraditional energies, e.g., vibration, laser, electric, etc., are applied to improve the machinability of local material and decrease burden of mechanical machining. It provides a feasible and promising way for improving machinability and surface quality, reducing process forces, and prolonging tool life, etc. However, systematic reviews of this technology are lacking with respect to the current research status and development direction. This paper reviews recent progress in nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community. It focuses on the processing principles, material responses under nontraditional energy, resultant forces and temperatures, material removal mechanisms and applications of these processes including vibration-, laser-, electric-, magnetic-, chemical-, cryogenic cooling-, and hybrid nontraditional energies-assisted mechanical machining. Eventually, a comprehensive summary of the principles, advantages and limitations for each hybrid process is provided, and future perspectives on forward design, device development and sustainability of nontraditional energy-assisted mechanical machining processes are discussed.

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“…This method provides support for the research on chip formation, cutting temperature prediction, microstructure evolution, cutting force and residual stress [21][22][23]. In addition, finite element technology has become an indispensable means to study the cutting mechanism of titanium alloys [24][25][26][27][28][29][30][31][32]. Davim et al [23] integrated many of the relevant aspects in the development of coolant assisted finite element method (FEM) simulations applied in difficult-to-cut materials, including titanium alloy.…”

Section: Introductionmentioning

confidence: 99%

Influence of cutting velocity on surface roughness during the ultra-precision cutting of titanium alloys based on a comparison between simulation and experiment

Lou

Chen

et al. 2023

PLoS ONE

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The Ti-6Al-4V titanium alloy is a kind of light alloy material with high specific strength, corrosion resistance and heat resistance. Because of its excellent performance, it has become an important material in aerospace industry. However, this kind of alloy has very poor machinability, and rapid tool wear is a very serious problem in titanium alloy processing. At present, it is difficult to guarantee the ultra-precision machining quality of titanium alloy materials, which limits its application in high-tech fields. In order to solve this problem, the influence of cutting speed on ultra-precision cutting process of titanium alloy was analyzed comprehensively. and it was found that better surface quality could be obtained at lower cutting speed. In order to study the influence of cutting speed in ultra-precision cutting of titanium alloys, cutting experiments have been carried out. Additionally, a finite element model was established to analyze the ultra-precision cutting process. Also, the constitutive model, damage model, friction model, and heat transfer in the modeling process were discussed. The chip morphology, cutting temperature, cutting force, and surface morphology under different cutting velocities are analyzed by simulation. Then, the simulation results were compared with the experimental results. The findings show that cutting speed has great influence on the ultra-precision turning of the Ti-6Al-4V alloy and the surface roughness obtained by ultra-precision cutting of titanium alloy can be lower than 20 nm at a lower cutting speed.

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Development of FEM-based digital twins for machining difficult-to-cut materials: A roadmap for sustainability

Cited by 15 publications

References 112 publications

Stochastic Evaluation of Cutting Tool Load and Surface Quality during Milling of HPL

Stochastic Evaluation of Cutting Tool Load and Surface Quality during Milling of HPL

Nontraditional energy-assisted mechanical machining of difficult-to-cut materials and components in aerospace community: a comparative analysis

Influence of cutting velocity on surface roughness during the ultra-precision cutting of titanium alloys based on a comparison between simulation and experiment

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