Modified Primary Shear Zone Analysis for Identification of Material Mechanical Behavior During Machining Process Using Genetic Algorithm

Pang, Lei; Kishawy, Hossam A.

doi:10.1115/1.4006768

Cited by 14 publications

(4 citation statements)

References 16 publications

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“…They have been used in a wide range of applications, including manufacturing processes to optimize system design and order pol icy [46], system identification to obtain model parameters [47,48], identification of manufacturing process parameters [49], assembly system reconfiguration planning [50], sheet roll forming [51] and folding [52], and shape optimization of orienting devices [53]. Stochastic search algorithms, however, can be computationally expensive and may break down in high dimension spaces such as those of continuum topology optimization.…”

Section: -4 / Vol 136 December 2014mentioning

confidence: 99%

Multiple-Material Topology Optimization of Compliant Mechanisms Created Via PolyJet Three-Dimensional Printing

Gaynor

Meisel

Williams

et al. 2014

Journal of Manufacturing Science and Engineering

238

110

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Compliant mechanisms are able to transfer motion, force, and energy using a monolithic structure without discrete hinge elements. The geometric design freedoms and multimate rial capability offered by the PolyJet 3D printing process enables the fabrication o f com pliant mechanisms with optimized topology. The inclusion of multiple materials in the topology optimization process has the potential to eliminate the narrow, weak, hingelike sections that are often present in single-material compliant mechanisms and also allow for greater magnitude deflections. In this paper, the authors propose a design and fabri cation process for the realization of 3-phase, multiple-material compliant mechanisms. The process is tested on a 2D compliant force inverter. Experimental and numerical per formance o f the resulting 3-phase inverter is compared against a standard 2-phase design.

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Section: -4 / Vol 136 December 2014mentioning

confidence: 99%

Multiple-Material Topology Optimization of Compliant Mechanisms Created Via PolyJet Three-Dimensional Printing

Gaynor

Meisel

Williams

et al. 2014

Journal of Manufacturing Science and Engineering

238

110

View full text Add to dashboard Cite

show abstract

“…15. Shear stresses, strain rate and temperature are significantly influenced by the change in geometry of primary shear zone [56]. The geometry of the primary shear zone is governed by the shear plane angle (∅ s ) and the ratio of the length of the primary shear zone (l AB ) to its thickness (t p ).…”

Section: Primary Shear Zonementioning

confidence: 99%

Smooth particle hydrodynamics study of surface defect machining for diamond turning of silicon

Mir

Luo

Siddiq

2016

Int J Adv Manuf Technol

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This paper presents the feasibility study of potential application of recently developed surface defect machining (SDM) method in the fabrication of silicon and similar hard and brittle materials using smooth particle hydrodynamics (SPH) simulation approach. Simulation study of inverse parametric analysis was carried out to determine the DruckerPrager (DP) constitutive model parameters of silicon by analysing the deformed material response behaviour using various DP model parameters. Indentation test simulations were carried out to perform inverse parametric study. SPH approach was exploited to machine silicon using conventional and surface defect machining method. To this end, we delve into opportunities of exploiting SDM through optimised machining quality, reduced machining time and lowering cost. The results of the conventional simulation were compared with the results of experimental diamond turning of silicon. In the SPH simulations, various types of surface defects were introduced on the workpiece prior to machining. Surface defects were equally distributed on the top face of the workpiece. The simulation study encompasses the investigation of chip formation, resultant machining forces, stresses and hydrostatic pressure with and without SDM. The study reveals the SDM process is an effective technique to manufacture hard and brittle materials as well as facilitate increased tool life. The study also divulges the importance of SPH evading the mesh distortion problem and offer natural chip formation during machining of hard and brittle materials.

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“…However, five constant parameters need to be known when using the Johnson-Cook material constitutive equation to calculate shear stress in orthogonal or oblique-angle cutting modeling. So, Pang et al [7] inversely identified the J-C constitutive parameters of AISI 1045 steel through cutting experiments. Firstly, the stress, strain, strain rate and temperature in the shear zone are calculated using the modified Oxley classical parallel shear band model.…”

Section: Introductionmentioning

confidence: 99%

Milling Force Modeling Methods for Slot Milling Cutters

Wu,

Zhang,

Wang

et al. 2023

Machines

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The slot milling cutter is primarily used for machining the tongue and groove of the steam turbine rotor, which is a critical operation in the manufacturing process of the steam turbine rotor. It is challenging to predict the milling force of a groove milling cutter due to variations in rake, rake angles and cutting speeds of the main cutting edge. Firstly, based on a limited amount of experimental data on turning, we have developed an equivalent turning force model that takes into account the impact of the rounded cutting edge radius, the tool’s tip radius and the feed rate on tool’s geometric angle. It provides a more accurate frontal angle for the identification method of the Johnson–Cook material constitutive equation. Secondly, the physical parameters, such as shear stress, shear strain and strain rate on the main shear plane, are calculated through the analysis of experimental data and application of the orthogonal cutting theory. Thirdly, the range of initial constitutive parameters of the material was determined through the split Hopkinson pressure bar (SHPB) test. The objective function was defined as the minimum error between the theoretical and experimental values. The optimal values of the Johnson–Cook constitutive equation parameters A, B, C, n and m are obtained through a global search using a genetic algorithm. Finally, the shear stress is determined by the governing equations of deformation, temperature and material. The axial force, torque and bending moment of each micro-segment are calculated and summed using the unit cutting force vector of each micro-segment. As a result, a milling force prediction model for slot milling cutters is established, and its validity is verified through experiments.

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Modified Primary Shear Zone Analysis for Identification of Material Mechanical Behavior During Machining Process Using Genetic Algorithm

Cited by 14 publications

References 16 publications

Multiple-Material Topology Optimization of Compliant Mechanisms Created Via PolyJet Three-Dimensional Printing

Multiple-Material Topology Optimization of Compliant Mechanisms Created Via PolyJet Three-Dimensional Printing

Smooth particle hydrodynamics study of surface defect machining for diamond turning of silicon

Milling Force Modeling Methods for Slot Milling Cutters

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