FEA modeling of orthogonal cutting of steel: a review

Orthogonal cutting is probably the most studied machining operation for metals. Its simulation with the Finite Element Analysis (FEA) method is of paramount academic interest. 2D models, and to a lesser extent 3D models, have been developed to predict cutting forces, chip formation, heat generation and temperature fields, residual stress distribution and tool wear. This paper first presents a brief review of scientific literature with focus on FEA modelling of the orthogonal cutting process for steels. Following, emphasis is put on the building blocks of the simulation model, such as the formulation of the mechanical problem, the material constitutive model, the friction models and damage laws

Investigation of cutting mechanics in single point diamond turning of silicon

As a kind of brittle material, silicon will undergo brittle fracture at atmospheric pressure in conventional scale machining. Studies in the last two decades on hard and brittle materials including silicon, germanium, silicon nitride and silicon carbide have demonstrated ductile regime machining using single point diamond turning (SPDT) process. The mirror-like surface finish can be achieved in SPDT provided appropriate tool geometry and cutting parameters including feed rate, depth of cut and cutting speed are adopted.The research work in this thesis is based on combined experimental and numerical smoothed particle hydrodynamics (SPH) studies to provide an inclusive understanding of SPDT of silicon. A global perspective of tool and workpiece condition using experimental studies along with localized chip formation and stress distribution analysis using distinctive SPH approach offer a comprehensive insight of cutting mechanics of silicon and diamond tool wear. In SPH modelling of SPDT of silicon, the distribution of von Mises and hydrostatic stress at incipient and steady-state was found to provide the conditions pertinent to material failure, phase transformation, and ductile mode machining. The pressure-sensitive Drucker Prager (DP) material constitutive model was adopted to predict the machining response behaviour of silicon during SPDT. Inverse parametric analysis based on indentation test was carried out to determine the unknown DP parameters of silicon by analysing the loading-unloading curve for different DP parameters. A very first experimental study was conducted to determine Johnson-Cook (J-C) model constants for silicon. High strain rate compression tests using split Hopkinson pressure bar (SHPB) test as well as quasi-static tests using Instron fatigue testing machine were conducted to determine J-C model constants.The capability of diamond tools to maintain expedient conditions for high-pressure phase transformation (HPPT) as a function of rake angle and tool wear were investigated experimentally as well as using SPH approach. The proportional relationship of cutting forces magnitude and tool wear was found to differ owing to wear contour with different rake angles that influence the distribution of stresses and uniform hydrostatic pressure under the tool cutting edge. A new quantitative evaluation parameter for the tool wear resistance performance based on the cutting distance was also proposed. It was also found that the machinability of silicon could be improved by adopting novel surface defect machining (SDM) method.The ductile to brittle transition (DBT) with the progressive tool wear was found to initiate with the formation of lateral cracks at low tool wear volume which transform into brittle pitting damage at higher tool edge degradation. A significant variation in resistance to shear deformation as well as position shift of the maximum stress values was observed with the progressive tool wear. The magnitude and distribution of hydrostatic stress were also found to change significantly along the cutting edge of the new and worn diamond tools.As a kind of brittle material, silicon will undergo brittle fracture at atmospheric pressure in conventional scale machining. Studies in the last two decades on hard and brittle materials including silicon, germanium, silicon nitride and silicon carbide have demonstrated ductile regime machining using single point diamond turning (SPDT) process. The mirror-like surface finish can be achieved in SPDT provided appropriate tool geometry and cutting parameters including feed rate, depth of cut and cutting speed are adopted.The research work in this thesis is based on combined experimental and numerical smoothed particle hydrodynamics (SPH) studies to provide an inclusive understanding of SPDT of silicon. A global perspective of tool and workpiece condition using experimental studies along with localized chip formation and stress distribution analysis using distinctive SPH approach offer a comprehensive insight of cutting mechanics of silicon and diamond tool wear. In SPH modelling of SPDT of silicon, the distribution of von Mises and hydrostatic stress at incipient and steady-state was found to provide the conditions pertinent to material failure, phase transformation, and ductile mode machining. The pressure-sensitive Drucker Prager (DP) material constitutive model was adopted to predict the machining response behaviour of silicon during SPDT. Inverse parametric analysis based on indentation test was carried out to determine the unknown DP parameters of silicon by analysing the loading-unloading curve for different DP parameters. A very first experimental study was conducted to determine Johnson-Cook (J-C) model constants for silicon. High strain rate compression tests using split Hopkinson pressure bar (SHPB) test as well as quasi-static tests using Instron fatigue testing machine were conducted to determine J-C model constants.The capability of diamond tools to maintain expedient conditions for high-pressure phase transformation (HPPT) as a function of rake angle and tool wear were investigated experimentally as well as using SPH approach. The proportional relationship of cutting forces magnitude and tool wear was found to differ owing to wear contour with different rake angles that influence the distribution of stresses and uniform hydrostatic pressure under the tool cutting edge. A new quantitative evaluation parameter for the tool wear resistance performance based on the cutting distance was also proposed. It was also found that the machinability of silicon could be improved by adopting novel surface defect machining (SDM) method.The ductile to brittle transition (DBT) with the progressive tool wear was found to initiate with the formation of lateral cracks at low tool wear volume which transform into brittle pitting damage at higher tool edge degradation. A significant variation in resistance to shear deformation as well as position shift of the maximum stress values was observed with the progressive tool wear. The magnitude and distribution of hydrostatic stress were also found to change significantly along the cutting edge of the new and worn diamond tools

Hybrid finite element–smoothed particle hydrodynamics modelling for optimizing cutting parameters in CFRP composites

Carbon-fibre-reinforced plastic (CFRP) is increasingly being used in various applications including aerospace, automotive, wind energy, sports, and robotics, which makes the precision modelling of its machining operations a critical research area. However, the classic finite element modelling (FEM) approach has limitations in capturing the complexity of machining, particularly with regard to the interaction between the fibre–matrix interface and the cutting edge. To overcome this limitation, a hybrid approach that integrates smoothed particle hydrodynamics (SPHs) with FEM was developed and tested in this study. The hybrid FEM-SPH approach was compared with the classic FEM approach and validated with experimental measurements that took into account the cutting tool’s round edge. The results showed that the hybrid FEM-SPH approach outperformed the classic FEM approach in predicting the thrust force and bounce back of CFRP machining due to the integrated cohesive model and the element conversion after failure in the developed approach. The accurate representation of the fibre–matrix interface in the FEM-SPH approach resulted in predicting precise chip formation in terms of direction and morphology. Nonetheless, the computing time of the FEM-SPH approach is higher than the classic FEM. The developed hybrid FEM-SPH model is promising for improving the accuracy of simulation in machining processes, combining the benefits of both techniques

Two-Dimensional Finite Element Analysis of Turning Processes

Despite crucial efforts invested into computational methods, explicit dynamics simulation of cutting operations may still be unacceptably expensive. Therefore, in many cases a two-dimensional model is considered. Here an overview of the possibilities of two-dimensional simulations is given. For this, simulation and measurement of a straight turning process on AISI 1045 steel is presented. In the numerical analysis, material behavior and its failure was described by Johnson-Cook law, considering damage evolution. Coupled thermo-mechanical model with mass-scaling and adaptive remeshing was built. The numerically obtained cutting force was compared to the measured data. It was found that the forces obtained with simulation and the measured ones show good agreement. Sensitivity analyses were performed to examine the influence of specific parameters on the reaction force. The effect of these parameters is also shown

Experimental Study And Modeling Of Mechanical Micro-machining Of Particle Reinforced Heterogeneous Materials

This study focuses on developing explicit analytical and numerical process models for mechanical micro-machining of heterogeneous materials. These models are used to select suitable process parameters for preparing and micro-machining of these advanced materials. The material system studied in this research is Magnesium Metal Matrix Composites (Mg-MMCs) reinforced with nano-sized and micro-sized silicon carbide (SiC) particles. This research is motivated by increasing demands of miniaturized components with high mechanical performance in various industries. Mg-MMCs become one of the best candidates due to its light weight, high strength, and high creep/wear resistance. However, the improved strength and abrasive nature of the reinforcements bring great challenges for the subsequent micro-machining process. Systematic experimental investigations on the machinability of Mg-MMCs reinforced with SiC nano-particles have been conducted. The nanocomposites containing 5 Vol.%, 10 Vol.% and 15 Vol.% reinforcements, as well as pure magnesium, are studied by using the Design of Experiment (DOE) method. Cutting forces, surface morphology and surface roughness are characterized to understand the machinability of the four materials. Based on response surface methodology (RSM) design, experimental models and related contour plots have been developed to build a connection between different materials properties and cutting parameters. Those models can be used to predict the cutting force, the surface roughness, and then optimize the machining process. An analytical cutting force model has been developed to predict cutting forces of MgMMCs reinforced with nano-sized SiC particles in the micro-milling process. This model is iv different from previous ones by encompassing the behaviors of reinforcement nanoparticles in three cutting scenarios, i.e., shearing, ploughing and elastic recovery. By using the enhanced yield strength in the cutting force model, three major strengthening factors are incorporated, including load-bearing effect, enhanced dislocation density strengthening effect and Orowan strengthening effect. In this way, the particle size and volume fraction, as significant factors affecting the cutting forces, are explicitly considered. In order to validate the model, various cutting conditions using different size end mills (100 µm and 1 mm dia.) have been conducted on Mg-MMCs with volume fraction from 0 (pure magnesium) to 15 Vol.%. The simulated cutting forces show a good agreement with the experimental data. The proposed model can predict the major force amplitude variations and force profile changes as functions of the nanoparticles’ volume fraction. Next, a systematic evaluation of six ductile fracture models has been conducted to identify the most suitable fracture criterion for micro-scale cutting simulations. The evaluated fracture models include constant fracture strain, Johnson-Cook, Johnson-Cook coupling criterion, Wilkins, modified Cockcroft-Latham, and Bao-Wierzbicki fracture criterion. By means of a user material subroutine (VUMAT), these fracture models are implemented into a Finite Element (FE) orthogonal cutting model in ABAQUS/Explicit platform. The local parameters (stress, strain, fracture factor, velocity fields) and global variables (chip morphology, cutting forces, temperature, shear angle, and machined surface integrity) are evaluated. Results indicate that by coupling with the damage evolution, the capability of Johnson-Cook and Bao-Wierzbicki can be further extended to predict accurate chip morphology. Bao-Wierzbiki-based coupling model provides the best simulation results in this study. v The micro-cutting performance of MMCs materials has also been studied by using FE modeling method. A 2-D FE micro-cutting model has been constructed. Firstly, homogenized material properties are employed to evaluate the effect of particles’ volume fraction. Secondly, micro-structures of the two-phase material are modeled in FE cutting models. The effects of the existing micro-sized and nano-sized ceramic particles on micro-cutting performance are carefully evaluated in two case studies. Results show that by using the homogenized material properties based on Johnson-Cook plasticity and fracture model with damage evolution, the micro-cutting performance of nano-reinforced Mg-MMCs can be predicted. Crack generation for SiC particle reinforced MMCs is different from their homogeneous counterparts; the effect of micro-sized particles is different from the one of nano-sized particles. In summary, through this research, a better understanding of the unique cutting mechanism for particle reinforced heterogeneous materials has been obtained. The effect of reinforcements on micro-cutting performance is obtained, which will help material engineers tailor suitable material properties for special mechanical design, associated manufacturing method and application needs. Moreover, the proposed analytical and numerical models provide a guideline to optimize process parameters for preparing and micro-machining of heterogeneous MMCs materials. This will eventually facilitate the automation of MMCs’ machining process and realize high-efficiency, high-quality, and low-cost manufacturing of composite materials

Identification of damage and fracture modes in power electronic packaging from experimental micro-shear tests and finite element modeling

Micro-shear tests are performed in order to characterize the mechanical behavior and the fracture of the chip/metallized ceramic substrate assemblies of power electronic devices. These assemblies are elaborated using three types of junctions: AuGe solder/Au or Ag finish, transient liquid phase bonding (TLPB) AgIn/Ag finish and Ag nanoparticles/Au or Ag finish. The experiments are associated to finite element simulations of both nano-indentation and micro-shear tests. The mechanical behavior of the different assembly interfaces is represented using an in-built cohesive zone model (CZM) available in the user friendly finite element code Abaqus. It is worth noting that the fracture mechanisms observed during the test and service periods of the power electronic packaging are not only due to the debonding at the interfaces but also to the initiation and growth of voids in the joint. Therefore, in addition to the CZM model, Gurson-Tvergaard-Needlmann (GTN) damage model is used in combination with the Rice bifurcation theory to correctly describe the fracture in the joint and, therefore the overall fracture mechanism of the entire junction. The simulation results are compared with the experimental force displacement curves and the SEM observations in order to assess the implemented model

Multi-Scale Modeling for Assessment of Sub-Surface Damage in Iron-Titanium Carbide Metal Matrix Composites

This study is concerned with investigating the effect of laser assisted machining on sub-surface damage during turning of iron-titanium carbide metal matrix composite (MMC) manufactured through laser direct deposition. A high-fidelity 3D multi-scale computational model is presented to predict the macroscopic and micromechanical response of the metal matrix composites undergoing laser assisted turning. Implementation of the multi-scale model has been realized through a hierarchical multi-scale modeling methodology where the results of interfacial mechanics for Fe-TiC composites determined from MD calculations have been used to parameterize the cohesive zone model in the finite element simulations. The 3D nose turning simulation model is capable of predicting the mechanics of cutting of composites, tool-particle interaction, cutting forces and sub-surface damage, hence providing a holistic framework for investigation of machinability of metal matrix composites. With the help of the simulation model, it has been discovered that the particles plough through the matrix material due to their increased concentration ahead of the cutting tool. This contributes to the dynamic loading of the machined workpiece in addition to loading from the secondary cutting edge of the tool. These two mechanisms collectively contribute towards sub-surface damage in the machined metal matrix composites. Damage analysis of Fe-TiC MMC revealed three-different types of damage mechanisms, namely particle pullout/fracture, interfacial debonding leading to void nucleation in matrix and coalescence of voids in the matrix. Localized heating of the Fe-TiC workpiece via a CO2 laser ahead of the cutting tool has been shown to be effective in reducing sub-surface debonding by approximately 20%. An experimental evaluation of the machinability of MMCs revealed a reduction in specific cutting energy by approximately 19%, a 20% improvement in tool life when using carbide tool at an optimum material removal temperature of 300 °C as compared to conventional machining after full annealing of the MMC

Investigation of Material Removal Mechanism in Grinding: A Single Grit Approach

This thesis has investigated material removal mechanisms in grinding by considering single grit workpiece interaction. The investigation was performed both experimentally and using finite element simulation. Rubbing, ploughing and cutting mechanisms occurring during the grinding process were studied at the micro scale. Due to its nature the rubbing phase occurs in a very narrow region of grit-workpiece engagement and is difficult to examine under a microscope and so was investigated using FEM simulation. The ploughing mechanism was thoroughly investigated using both experimental tests and FEM simulations, and a similar trend was observed for the pile up ratio along the scratch path from the experimental tests and the FEM simulations. Ploughing and cutting mechanisms in grinding were found to be highly influenced by grit cutting edge shape, sharpness and bluntness. Cutting is the prominent mechanism when the grit cutting edge is sharp, but ploughing is more prominent when the grit cutting edge becomes flattened. In the case of multiple edges scratch formation, ploughing is dramatically increased compared to single edge scratches. Feasibility of ground surface simulation using FEM is demonstrated using multiple pass scratch formation in a cross direction. Although chip formation mechanism is developed at a relatively higher depth of cut (greater than 10 μm), at small scales down to 1 μm, FEM simulation was not a suitable method to use. To reduce the drawbacks of FEM simulation in micro scale cutting, a meshless simulation technique such as smooth particle hydrodynamics is recommended for future studies