From the basic mechanics of orthogonal metal cutting toward the identification of the constitutive equation

Tounsi, Nejah; Vincenti, J.; Otho, Alain; Elbestawi, M.A.

doi:10.1016/s0890-6955(02)00046-9

Cited by 214 publications

(121 citation statements)

References 7 publications

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“…This observation could explain the rule of the thumb when machining of CFRP: high cutting speed and low feed rate. Tounsi et al, (2002) found similar results and they showed that under this condition (minimum feed and maximum cutting speed), it was much easier to soften low quantities of CFRP with the generated heat due to friction. In terms of energy consumption, Test 3 (maximum feed rate and minimum cutting speed) had the highest level of cutting forces and the CNC machine consumed more energy while Test 1 (minimum feed and maximum cutting speed) had the lowest level of cutting forces and the CNC machine consumed less energy during tool life experiments.…”

Section: Cutting Forces Analysissupporting

confidence: 54%

Effect of Tool Wear on Quality of Carbon Fiber Reinforced Polymer Laminate during Edge Trimming

Hamedanianpour

Châtelain

2013

AMM

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Polymer matrix composites, particularly carbon fiber reinforced polymers (CFRPs) are widely used in various high technology industries, including aerospace, automotive and wind energy. Normally, when CFRPs are cured to near net shape, finishing operations such as trimming, milling or drilling are used to remove excess materials. The quality of these finishing operations is highly crucial at the level of final assembly. The present research aims to study the effect of cutting tool wear on the resulting quality for the trimming process of high performance CFRP laminates, in the aerospace field. In terms of quality parameters, the study focuses on surface roughness and material integrity (uncut fibers, fiber pull-out, delamination or thermal damage of the matrix), which could jeopardize the mechanical performance of the components. In this study, a 3/8 inch diameter CVD diamond coated carbide tool with six straight flutes was used to trim 24-ply carbon fiber laminates. Cutting speeds ranging from 200 m/min to 400 m/min and feed rates ranging from 1524 mm/min to 4064 mm/min were used in the experiments. The results obtained using a scanning electron microscope (SEM) showed increasing defect rates with increased tool wear. The worst surface integrity, including matrix cracking, fiber pull-out and empty holes, was also observed for plies oriented at -45 degrees. For the surface finish, it was observed that for the studied cutting length ranges, an increase in tool wear resulted in a decrease in surface roughness. Regarding tool wear, a lower rate was observed at lower feed rates and higher cutting speeds, while a higher tool wear rate was observed at intermediate values of our feed rate and cutting speed ranges.

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Section: Cutting Forces Analysissupporting

confidence: 54%

Effect of Tool Wear on Quality of Carbon Fiber Reinforced Polymer Laminate during Edge Trimming

Hamedanianpour

Châtelain

2013

AMM

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“…This penalizes numerical analysts who use phenomenological and very simple models (such as the Johnson-Cook model [17]) [26], the identification of which requires only a few tests [5,27] and that have a limited range of validity, which is more restrictive than the range of the rheological parameters observed in machining or forging operations. Also, it is possible to find in the literature different values of the same model parameters for identical materials [28,29].…”

Section: Discussionmentioning

confidence: 99%

“…The available studies are based on experimental data which is often very limited. In general a minimum number of tests are done in order to identify the chosen constitutive model without comparing its domain of validity with the loads applied to the material during machining [5] or forging [6].…”

Section: Introductionmentioning

confidence: 99%

An experimental investigation of the behaviour of steels over large temperature and strain rate ranges

Hor

Morel

Lebrun

et al. 2013

International Journal of Mechanical Sciences

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is an open access repository that collects the work of Arts et Métiers ParisTech researchers and makes it freely available over the web where possible. During forging and machining manufacturing processes, the material is subject to large strains at high strain rates which provoke local heating and microstructural changes. Modelling of these phenomena requires precise knowledge of the stress-strain constitutive equations for a large range of strains, strain rates and temperatures. An experimental study of the rheology of both hyper-and hypo-eutectoid steels (with different microstructures) over a temperature range from 20 1C to 1000 1C and with strain rates from 10 À2 to 10 5 s À1 has been undertaken. These tests were performed in compression on cylindrical specimens and in shear using hat-shaped specimens. Both a GLEEBLE 3500 thermomechanical testing machine and a Split-Hopkinson Pressure Bar apparatus were used. From these tests, three deformation domains have been identified as a function of the material behaviour and of the changes in the deformed microstructure. Each domain was characterized by its behaviour, including the competition between hardening and softening, strain rate sensitivity on the flow stress and the softening phenomenon (i.e. recrystallisation or recovery, etc.). Finally, based on thermodynamical considerations, the conditions of thermoplastic instability (i.e. shear bands, twinning, heterogeneities, etc.) and microstructural changes are highlighted using process maps of the dissipated power repartition.

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“…Nasr et al [49] showed a considerable increase in residual stresses when initial yield stress (A) decreases and when the strain hardening parameters (B and n) increase. Some authors recommend, in the absence of any dedicated mechanical test method for describing the flow stress, the use of metal cutting results (cutting forces and chip morphology) to fit the constants of the Jonhson-Cook law [50]. In the present work the same approach was followed, starting from values proposed by other authors and proposing a new set that fits the values of cutting forces obtained experimentally (see Table 1).…”

Section: Model Descriptionmentioning

confidence: 96%

Residual Stresses in Orthogonal Cutting of Metals: The Effect of Thermomechanical Coupling Parameters and of Friction

Miguélez

Zaera

Molinari

et al. 2009

Journal of Thermal Stresses

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The generation of residual stresses in orthogonal machining is analysed by using an Arbitrary Lagrangian Eulerian (ALE) finite element approach. It is shown that a substantial level of tensile residual stresses can be obtained in the vicinity of the machined surface without any contribution of thermal effects. This motivates the development of a parametric study to analyse the effects of the thermomechanical coupling parameters on residual stresses. The roles of thermal expansion, of thermal softening and of the Taylor-Quinney coefficient (controlling the heat generated by plastic flow) are considered separately. The influence of friction is also analysed by assuming dry cutting conditions and a Coulomb friction law. The friction coefficient has a complex effect by controlling heat generation (frictional heating) along the tool rake and clearance faces and the propensity for the chip to stick to the tool. Geometrical effects such as the tool rake angle and the tool edge radius are also discussed.

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From the basic mechanics of orthogonal metal cutting toward the identification of the constitutive equation

Cited by 214 publications

References 7 publications

Effect of Tool Wear on Quality of Carbon Fiber Reinforced Polymer Laminate during Edge Trimming

Effect of Tool Wear on Quality of Carbon Fiber Reinforced Polymer Laminate during Edge Trimming

An experimental investigation of the behaviour of steels over large temperature and strain rate ranges

Residual Stresses in Orthogonal Cutting of Metals: The Effect of Thermomechanical Coupling Parameters and of Friction

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