Finite element analysis of orthogonal cutting of cellular metals: influence of cutting conditions on chip formation and surface damage

Silva, Rafael Guerra; Teicher, Uwe; Ihlenfeldt, Steffen; González-Zamora, Arístides

doi:10.1007/s00170-021-06689-0

Cited by 4 publications

(1 citation statement)

References 23 publications

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“…One of his findings was a reduction in thrust forces when porosity content increased, mainly due to the brittle fractures around the pores leading to reduced cutting forces. Guerra-Silva et al [ 16 ] performed an analysis on the influence of machining conditions and tool geometrical features on the orthogonal machining of cellular heat-resistant austenitic stainless steel by means of an FE simulation model. The key conclusion drawn by the authors is the increased cutting force with higher cutting speed and/or feed rate due to the non-homogeneous nature of the metal (presence of foam).…”

Section: Introductionmentioning

confidence: 99%

Computational Analysis of Machining Induced Stress Distribution during Dry and Cryogenic Orthogonal Cutting of 7075 Aluminium Closed Cell Syntactic Foams

et al. 2023

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The addition of hollow aluminium oxide bubbles to the 7075 aluminium matrix results in a lightweight syntactic foam with a reduced density and an increased peak compression strength. The presence of ceramic bubbles also aids in a reduced coefficient of thermal expansion and thermal conductivity in comparison to aluminium alloys. In spite of their enhanced material properties, the inclusion of hollow aluminium oxide bubbles presents the challenge of poor machinability. In order to elucidate the problem of poor surface machinability, an attempt has been made to develop a thermo-mechanical finite element machining model using AdvantEdgeTM software with which surface quality and machined syntactic foam material can be analyzed. If the novel model developed is combined with virtual reality technology, CNC technicians can observe the machining results to evaluate and optimize the machining program. The main novelty behind this software is that the material foam is assumed as a homogeneous material model for simplifying the material model as a complex heterogeneous material system. The input parameters used in this study are cutting speed, feed, average size and volume fraction of hollow aluminium oxide bubbles, and coolant. For the output parameters, the numerical analysis showed a 6.24% increase in peak tensile machining induced stress as well as a 51.49% increase in peak cutting temperature as cutting speed (25 m/min to 100 m/min) and uncut chip thickness (0.07 mm to 0.2 mm) were increased. The average size and volume fraction of hollow aluminium oxide bubbles showed a significant impact on the magnitude of cutting forces and the depth of tensile induced stress distribution. It was observed on the machined surface that, as the average size of hollow aluminium oxide bubbles became coarser, the peak machining induced tensile stress on the cut surface reduced by 4.47%. It was also noted that an increase in the volume fraction of hollow aluminium oxide bubbles led to an increase in both the peak machining induced tensile stress and the peak cutting temperature by 29.36% and 20.11%, respectively. This study also showed the influence of the ceramic hollow bubbles on plastic deformation behavior in 7075 aluminium matrix; the machining conditions for obtaining a favorable stress distribution in the machined surface and sub-surface of 7075 closed cell syntactic foam are also presented.

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Section: Introductionmentioning

confidence: 99%

Computational Analysis of Machining Induced Stress Distribution during Dry and Cryogenic Orthogonal Cutting of 7075 Aluminium Closed Cell Syntactic Foams

et al. 2023

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Transition of material removal mechanism in cutting of unidirectional SiCf/SiC composites

Chen,

Gong,

Song

et al. 2024

Int J Adv Manuf Technol

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Investigating the Surface Quality of Aramid Honeycomb Materials Through Longitudinal–Torsional Ultrasonic Milling

Zhang,

Hong,

et al. 2024

Machines

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During the milling process of aramid honeycomb, residual stresses arise, which will affect the surface quality of the honeycomb. Studies have shown that reasonable processing techniques can reduce residual stresses, indicating a close relationship between residual processing stresses and the processing parameters, such as technique. By investigating the changes in residual stresses after the processing of aramid honeycomb materials, the influence of processing techniques on these changes is analyzed. Leveraging the correlation between residual stresses and surface quality, this study proposes the use of residual stress as an indicator for evaluating processing techniques. The longitudinal–torsional ultrasonic vibration milling method is applied to the processing of aramid honeycombs. A single-factor experimental approach is adopted, utilizing ABAQUS 2020 software to mimic the longitudinal–torsional ultrasonic milling process. This study explores the influence patterns of various process parameters on the residual stresses generated during the milling of honeycombs. The simulation results indicate that within the selected range, the residual stress decreases as the tool rotation speed increases, while it increases with the increase in feed rate. The influence of milling depth on residual stress can be negligible. Furthermore, experiments were conducted based on the proposed correlation between residual stress and surface quality. The experimental results show good agreement with the simulation results, indicating that under reasonable process parameters, the residual stress values decrease, thereby improving the milling surface quality of aramid honeycomb materials. Therefore, measuring residual stress can serve as an effective method for evaluating the processing technique.

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Finite element analysis of orthogonal cutting of cellular metals: influence of cutting conditions on chip formation and surface damage

Cited by 4 publications

References 23 publications

Computational Analysis of Machining Induced Stress Distribution during Dry and Cryogenic Orthogonal Cutting of 7075 Aluminium Closed Cell Syntactic Foams

Computational Analysis of Machining Induced Stress Distribution during Dry and Cryogenic Orthogonal Cutting of 7075 Aluminium Closed Cell Syntactic Foams

Transition of material removal mechanism in cutting of unidirectional SiCf/SiC composites

Investigating the Surface Quality of Aramid Honeycomb Materials Through Longitudinal–Torsional Ultrasonic Milling

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