Simulation of the orthogonal metal cutting process using an arbitrary Lagrangian–Eulerian finite-element method

Movahhedy, Mohammad R.; Gadala, Mohamed S.; Altintaş, Yusuf

doi:10.1016/s0924-0136(00)00480-5

Cited by 155 publications

(57 citation statements)

References 21 publications

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“…Detailed formulation for an A.L.E. approach can be found in different references, see for instance [32]. A brief summary of the theoretical fundamentals for A.L.E.…”

Section: Numerical Model and Experimental Validationmentioning

confidence: 99%

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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“…Detailed formulation for an A.L.E. approach can be found in different references, see for instance [32]. A brief summary of the theoretical fundamentals for A.L.E.…”

Section: Numerical Model and Experimental Validationmentioning

confidence: 99%

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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“…Finite element analysis of metal cutting using Lagrangian [24,25], Eulerian and Arbitrary Lagrangian-Eulerian [26] approaches have been extensively exploited. However, machining of hard materials using positive and particularly negative rake angle tools is still a challenge due to high mesh distortion.…”

Section: Vibration-assisted Machiningmentioning

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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“…Kalhori [16] conducted different studies on metal cutting; adaptive remeshing was employed in two models developed for the FEM codes SiMPle and AdvantEdge. Movahhedy et al [17,18] studied the influence of cutting edge geometry on the chip removal process, simulating sharp, blunt and chamfered tools; such analysis was based on ALE formulation. Yang and Liu [19] focused on the impact of the friction coefficient on residual stress patterns, presenting a new stress-based polynomial model of friction; the main drawback of their approach was the need to have an experimental evaluation of the friction coefficient all along the tool rake face for a particular cutting condition and a specific workpiece material.…”

Section: Introductionmentioning

confidence: 99%

Prediction of residual stress distribution after turning in turbine disks

Salio

Berruti

Poli

2006

International Journal of Mechanical Sciences

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Simulation of the orthogonal metal cutting process using an arbitrary Lagrangian–Eulerian finite-element method

Cited by 155 publications

References 21 publications

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

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

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

Prediction of residual stress distribution after turning in turbine disks

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