Multi-scale method for recognizing damage in high-efficiency milling cutter

Jiang, Bin; Xu, Xingliang; Zhao, Peiyi; Fan, Lili; Gu, Yunpeng

doi:10.1007/s00170-020-05159-3

Cited by 2 publications

(1 citation statement)

References 21 publications

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“…It provides a promising approach to reduce the computational load while improving the reliability of FEM-based cutting simulations. Typically, Molecular dynamics (MD) [11,12] Several dislocations interaction details Heavy computational burden and limited simulation scale Mesoscopic calculation (μm to mm) Dislocation dynamics (DD) [13,14] Massive dislocation evolution details Inapplicable to capture the microstructural alteration Multiscale modeling (nm to mm) Quasicontinuum (QC) [15] Improved size scale of MD simulation scale A theoretical gap in coupling between atomistic scale to macroscale Cross-scale model (MD-FEM) [16] Cellular automaton (CA-FEM) [17] Complex topological microstructure evolution…”

Section: Introductionmentioning

confidence: 99%

A novel multiscale material plasticity simulation model for high-performance cutting AISI 4140 steel

Bai

Tong

2021

Int J Adv Manuf Technol

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The achievable machined surface quality relies significantly on the material behavior during the high-performance cutting process. In this paper, a multiscale material plasticity simulation framework is developed to predict the deformation behaviors of AISI 4140 steel under various high-performance cutting conditions. The framework was built by coupling a three-dimensional discrete dislocation dynamic (3D-DDD) model with a finite element method (FEM) through the optimization of a dislocation density-based (DDB) constitutive equation (compiled as a user-defined subroutine in ABAQUS). The movement of edge and screw dislocations such as generation, propagation, siding, and their interactions, was performed by 3D-DDD, and the statistical features of dislocations were used to optimize the critical constants of the DDB constitutive equation. For validation, a classic FEM cutting model (Johnson-Cook constitutive equation) was employed as a reference. The simulation results indicated that the proposed multiscale model not only can precisely predict the stress, strain, cutting force, and temperature as those predicted by the classic FEM simulations, but also capture the microstructure characteristics such as grain size and dislocation density distributions under the tested cutting conditions. Severe dynamic recrystallization phenomena were found at the core shear zones. The recrystallization process reached a dynamic equilibrium at the machined surfaces when the cutting speed is larger than 280 m/min or the external-assisted temperature is between 200 and 350°, indicating an optimal range of machining parameters for improved surface integrity.

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Section: Introductionmentioning

confidence: 99%

A novel multiscale material plasticity simulation model for high-performance cutting AISI 4140 steel

Bai

Tong

2021

Int J Adv Manuf Technol

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Distribution and Prediction of Incremental Cutter Flank Wear in High-Efficiency Milling

et al. 2023

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In the milling of titanium alloy workpieces, tool wear seriously affects the surface quality of a workpiece and its tool life. It is of great significance to study the influence of instantaneous contact stiffness on instantaneous friction variables and incremental wear, which is of great significance for the realization of control over the degree of flank wear and improving the service life of cutter teeth. In this paper, an experiment to monitor cutting with a Ti6Al4V workpiece with a high-feed milling cutter was carried out; according to the experimental results, the wear area of the flank face of the cutter tooth was determined. The feature points of the flank were selected, and an instantaneous contact stiffness calculation method for the flank was proposed. The infinitesimal method was used to characterize the distribution of the contact stiffness of the flank, and the evolution characteristics of instantaneous contact stiffness distribution under the influence of vibration were obtained. According to the calculation results, the instantaneous distribution of flank wear depth was calculated. A grey correlation degree was used to reveal the correlation between the instantaneous contact stiffness of the flank face and wear depth, and a positionable wear-prediction model based on the instantaneous contact stiffness of the flank was proposed. Based on a BPNN (back propagation neural network), a prediction model for flank wear was established. The results showed that the above model and method could accurately predict the instantaneous wear of the tool flank.

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Multi-scale method for recognizing damage in high-efficiency milling cutter

Cited by 2 publications

References 21 publications

A novel multiscale material plasticity simulation model for high-performance cutting AISI 4140 steel

A novel multiscale material plasticity simulation model for high-performance cutting AISI 4140 steel

Distribution and Prediction of Incremental Cutter Flank Wear in High-Efficiency Milling

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