Experimental and Computational Investigation of Machining Processes for Functionally Graded Materials

Biermann, Dirk; Menzel, Andreas; Bartel, Thorsten; Höhne, Franziska; Holtermann, Raphael; Ostwald, Richard; Sieben, Benjamin; Tiffe, M.; Zabel, Andreas

doi:10.1016/j.proeng.2011.11.074

Cited by 8 publications

(2 citation statements)

References 4 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The applied material model is stored by default in the DEFORM TM 3D material library and it includes several stress-strain curves for different temperatures that have been identified experimentally. Additionally for these research activities, the yield point was adjusted for the hardened material corresponding to the values identified by a tensile test [1]. …”

Section: Materials Modelingmentioning

confidence: 99%

Finite element modeling and three-dimensional simulation of the turning process incorporating the material hardness

et al. 2010

View full text Add to dashboard Cite

Newly developed functionally graded workpieces made of AISI 6150 (51CrV4), pose great challenges to the machining process due to the combination of different material properties (e.g., hardness) within one workpiece. A material model including more information than experimentally identified stress-strain curves for different temperatures is necessary to model the process more realistically. Therefore, the Johnson-Cook material model has been implemented for three-dimensional turning simulations within the Finite Element software DEFORM TM 3D. This paper outlines the adopted method to modify the parameters of the Johnson-Cook material model for two-dimensional and threedimensional FE-simulations in order to take material hardness into account. The primary objective was to improve passive and feed force computation by using this modeling approach, as it was observed that common material modeling showed large deviations of the feed force and passive force from the measured force components. The calculated feed force and passive force, as well as the cutting force, are validated experimentally. In conclusion it is shown that the application of the Johnson-Cook material model reveals more valid results for modeling the turning of workpieces with varying hardness values.

show abstract

Section: Materials Modelingmentioning

confidence: 99%

Finite element modeling and three-dimensional simulation of the turning process incorporating the material hardness

et al. 2010

View full text Add to dashboard Cite

show abstract

“…Alexandrov et al 16 have presented a numerical/analytical model to predict the pure bending of FGM sheets at large strains; the distribution of residual stresses and the spring back are included in this method. Despite the above-mentioned research works, there has been a lack of research on FGMs in various manufacturing processes: A study by Biermann et al 17 determined that compressive residual stresses accumulate at hardened zones and tensile ones in non-hardened zones during the dry face-turning process of functionally graded steels using polycrystalline cubic boron nitride tools. A study by Seo et al 18 on electro-discharge machining of an SiCp/Al functionally graded metal matrix composite (MMC).…”

Section: Introductionmentioning

confidence: 99%

An optimized irradiation strategy and layout configuration in laser forming of copper/aluminum bi-metal sheets with a functional thickness

Ghoreishi

Mahmoodi

2022

Proceedings of the Institution of Mechanical Engineers, Part L:

View full text Add to dashboard Cite

Laser forming process is a type of thermo-mechanical forming process in which a laser beam irradiation on a specific scan path is used to create a bending angle in a sheet. In this work, the forming behavior of copper/aluminum bi-metal sheets with a functional thickness is investigated using the laser forming process. For that, numerical simulations are performed with an implementation of DFLUX subroutine to have more realistic process circumstances. The process parameters were defined as follows: laser beam radius of 2 mm and scan velocity of 1000 mm/min with three different laser power to activate the temperature gradient mechanism. A detailed discussion has been done on an optimized selection of bi-metal sheet layout (i.e. the selection of the material from copper and aluminum as the top layer to increase the formability of the sheet under the same process conditions). Furthermore, the laser forming process of bi-metal sheets with a functional thickness as well as single-layered uniform sheets have been studied and the differences between these two are specified. An irradiation strategy was also presented to eliminate/reduce edge effects on bi-metal sheets. Hence, by adding an auxiliary laser path perpendicular to the main scan path, the uniformity of the final product would be improved. Numerical simulations were fully validated with the corresponding experimental tests. Finally, aluminum was determined as the ideal option to choose as a top layer due to having a higher thermal expansion coefficient and lower thermal conductivity.

show abstract

Towards the simulation of Internal Traverse Grinding – from mesoscale modelling to process simulations

Holtermann

Menzel

2012

Proc Appl Math and Mech

View full text Add to dashboard Cite

The present work aims at the modelling and simulation of Internal Traverse Grinding of hardened 100Cr6/AISI 52100 using electro plated cBN grinding wheels. We focus on the thermomechanical behaviour resulting from the interaction of tool and workpiece in the process zone on a mesoscale.Based on topology analyses of the grinding wheel surface, two‐dimensional single‐ and multigrain representative numerical experiments are performed to investigate the resulting load‐displacement‐behaviour as well as the specific heat generation due to friction and plastic dissipation.A thermoelastic‐viscoplastic constitutive model is used to capture thermal softening of the material taken into account. Based on previous work, an adaptive remeshing scheme which uses a combination of error estimation and indicator methods, is applied to overcome mesh dependence. In consequence, the formulation allows to resolve the complex deformation patterns and to predict a realistic thermomechanical state of the resulting workpiece surface. (© 2012 Wiley‐VCH Verlag GmbH & Co. KGaA, Weinheim)

show abstract

Experimental and Computational Investigation of Machining Processes for Functionally Graded Materials

Cited by 8 publications

References 4 publications

Finite element modeling and three-dimensional simulation of the turning process incorporating the material hardness

Finite element modeling and three-dimensional simulation of the turning process incorporating the material hardness

An optimized irradiation strategy and layout configuration in laser forming of copper/aluminum bi-metal sheets with a functional thickness

Towards the simulation of Internal Traverse Grinding – from mesoscale modelling to process simulations

Contact Info

Product

Resources

About