Modelling of Machining Operations

Author: Outeiro J.C.  

Publisher: Trans Tech Publications‎

Publication year: 2011

E-ISBN: 9783038135951

P-ISBN(Paperback): 9783037850954

Subject: TB3 Engineering Materials

Keyword: 工程材料学

Language: ENG

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Description

Volume is indexed by Thomson Reuters CPCI-S (WoS).The modelling of Machining Operations has become very widespread today, with many researchers developing models with which to predict metal-cutting performance. The aim here is to provide an answer to the challenges presented by the machining industry, which is presently facing very tight economical and environmental constraints. The collection of over 100 peer-reviewed papers covers twelve research topics, including: “Analytical and Numerical Modelling”; “Cutting Fundamentals: Input Parameters”; “Cutting Fundamentals: Experimental Validation”; “Surface Integrity”; “Surface Topography”; “Tool Wear and Tool Life”; “Dynamics and Stability”; “High-Speed Machining and 5-Axes Machining”; “Abrasive Machining”; “Ultra-Precision and Micromachining”; “Computer-Aided Manufacturing (CAM)”; “Experimental: Non-Conventional Machining”. This work will thus constitute an invaluable handbook on the subject. In addition to the analytical and numerical modeling of metal cutting, the 100 papers selected for the May 2011 conference present recent advances in surface integrity, input parameters, tool wear, milling dynamics, stability, and abrasive machining. Finite element models analyze the effect of cut depth on chip formation during orthogonal cutting, kinematics and chip formation during gear skiving, the stability of coatings, and pilot hole drilling in aluminum. Three papers on five-axis milling propose a tool path smoothing algorith

Chapter

An Analytical Thermomechanical Modelling of Peripheral Milling Process Using a Predictive Machining Theory

Analytical Model of Chip Formation in Case of Orthogonal Cutting Processes

CFRP Drilling Model: Fiber Orientation Influence on Mechanical Load and Delamination

Numerical Model for Prediction of Cutting Force in Peripheral Milling Process Including Thrust and Tangential Damping

FEM Based Design of a Chip Breaker for the Machining with PCD Tools

3D FEM Model for the Prediction of Chip Breakage

A Numerical and Experimental Investigation of the Deformation Zones and the Corresponding Cutting Forces in Orthogonal Cutting

On Methodologies inside Two Different Commercial Codes to Simulate the Cutting Operation

Application of the Nodal Integrated Finite Element Method to Cutting: a Preliminary Comparison with the “Traditional” FEM Approach

Validation of Finite Element Modeling of Drilling Processes with Solid Tooling in Metals

Coating-Substrate-Simulation with an Advanced Adaptive Finite Element Code

Virtual Reality Animation of Chip Formation during Turning

Energy Efficient Process Planning Based on Numerical Simulations

Simulation of the Temperature Distribution in NC-Milled Workpieces

Numerical Prediction of the Interface Temperature Using Updated Finite Difference Approach

Effect of Cutting Conditions on Temperature Generated in Drilling Process: a FEA Approach

Analysis of Forces and Temperatures in Conventional and Ultrasonically-Assisted Cutting of Bone

Chapter 2: Cutting Fundamentals: Input Parameters

Input Data for the Numerical Simulation of Metal Cutting

Inverse Flow Stress Calculation for Machining Processes

Inverse Identification of Johnson-Cook Material Parameters from Machining Simulations

New Thermal Issues on the Modelling of Tool-Workpiece Interaction: Application to Dry Cutting of AISI 1045 Steel

Finite-Element Simulations of Split Hopkinson Test of Ti-Based Alloy

The Numerical Investigation of Stress Distribution on the Rake Face for Grooved Cutting Tool Inserts

Calibration of the Rheological Model Considering the Temperature in Milling Operation of Ti-6Al-4V: a Preliminary Analysis

Chapter 3: Cutting Fundamentals: Experimental Validation

Deformation and Microstructure in Machining

Strain Rate Effect on the Mechanical Behavior of Austenitic Stainless Steel during Machining

Technological and Environmental Aspects in Milling of γ-TiAl

Evaluation of the Cutting Force and Geometric Error for Roughing Operation by Plunge Milling

A Metal Cutting Approach to Investigate the Tribological Properties of Nano Crystalline Boric Acid and the Effect of its Carrying Medium

Chapter 4: Surface Integrity

Modeling the Process-Induced Modifications of the Microstructure of Work Piece Surface Zones in Cutting Processes

Analytical and Numerical Modeling of Strain Hardening in AISI 304 Steel Cutting

A Hybrid Approach to Predict Residual Stresses Induced by Ball-End Tool Finishing Milling of a Bainitic Steel

Prediction of Machining Induced Surface Integrity Using Elastic-Viscoplastic Simulations and Temperature-Dependent Flow Softening Material Models in Titanium and Nickel-Based Alloys

3D Numerical Prediction of Residual Stresses in Turning of 15-5PH

Prediction of Residual Stresses in Turning of Inconel 718

Residual Stress Prediction by Means of 3D FEM Simulation

Analysis of Surface Integrity in Dry and Cryogenic Machining of AZ31B Mg Alloys

Influence of Worn Tool on Polishability and Wear Resistance of VP20ISO Mold Steel

High-Speed Milling Characteristics and the Residual Stresses Control Methods Analysis of Thin-Walled Parts

Influence of Hard and Soft Inclusions on the Machinability and Polishability of VP100 Mold Steel

Analysis of Surface Integrity for DIN 100Cr6 Steel Conical Bearing Rings after Hard Turning

Surface Integrity Functional Analysis in Hard Turning AISI 8620 Case Hardened Steel through 3D Topographical Measurement

Chapter 5: Surface Topography

Modeling and Characterization of Surface Structures Produced by Milling

Identification of Surface Generation Mechanisms Based on Process Feed-Back and Decomposition of Feed Marks

Modulation-Assisted Machining: A New Paradigm in Material Removal Processes

Chapter 6: Tool Wear and Tool Life

Tool Load during Multi-Flank Chip Formation

Development of a Simulation Model to Investigate Tool Wear in Ti-6Al-4V Alloy Machining

Modeling and Optimization of Multiple Characteristics in the AISI 52100 Hardened Steel Turning

Life Prediction of Cutting Tool by the Workpiece Cutting Condition

An XPS Study of the Stratified Built-up Layers Developed onto the Tool Surface in the Dry Drilling of Ti Alloys

Experimental Design Applied to the Machining of Windows Cage Ball Joints Homokinetic SAE 8620 Steel with CBN Tool

Analysis of Sintering Parameters by SPS on Cemented Carbide

Chapter 7: Dynamics and Stability

Dynamic Study of Thin Wall Part Turning

Stability Analysis of Machining with Spindle Speed Variation

Investigating Dynamics of Machine Tool Spindles under Operational Conditions

Fixed Boundaries Receptance Coupling Substructure Analysis for Tool Point Dynamics Prediction

A Novel Approach to Thin-Wall Machining of Aerospace Structures - Stability Margin Prediction Using a New Damping Modelling Approach

The Influence of Process Machine Interactions on the Stability of Parallel Milling

Modeling the Varying Dynamics of Thin-Walled Aerospace Structures for Fixture Design Using Genetic Algorithms

FEA-Methodology for the Prediction of Aluminium Thin Walled Part Deformation in Dry Milling Operations

Modeling and Analysis Effects of Material Removal on Machining Dynamics in Milling of Thin-Walled Workpiece

A New Experimental Setup and Method to Analyze Cutting Forces in Non-Stationary Conditions

Chapter 8: High Speed Machining and 5 Axes Machining

5-Axis Flank Milling Tool Path Smoothing Based on Kinematical Behaviour Analysis

Modeling Cutting Forces for Five Axis Milling of Sculptured Surfaces

Mechanistic Model Based on the Actual Removal Volume during Simultaneous Five-Axis Milling

Optimization of High Speed Machine Tool Frames

Chapter 9: Abrasive Machining

FEM-Based Simulation of Temperature in Speed Stroke Grinding with 3D Transient Moving Heat Sources

Modeling and Simulation of Phase Transformation during Grinding

Modeling of a Polishing Tool to Simulate Material Removal

Finite Element Simulation of Quick – Stop Experiments for Better Understanding of Chip Formation in Grinding

Optimization of Process Parameters in CFRP Machining with Diamond Abrasive Cutters

Theoretical and Experimental Determination of Geometry Deviation in Continuous Path Controlled OD Grinding Processes

Kinematic Model for Ultrasonic-Assisted Manufacturing of Bore Holes with Undefined Cutting Edges

Machinability Evaluation in the Ultrasonic Drilling (USD) Process of Aluminum Oxide-based Ceramics

FEM Simulation of Strain Rate in High Speed Grinding

Evaluation of Quality of Steering Systems Using the Honing Process and Surface Response Methodology

Study on the Simulation Model and High-Speed Characteristics of Cylindrical Grinding

Chapter 10: Ultra-Precision and Micromachining

Modelling of Ultra-Precision Turning Processes in Consideration of Unbalances

Simulation Model for Micro-Milling Operations and Surface Generation

Effects of the Cutting Tool Edge Radius on the Stability Lobes in Micro-Milling

An Experimental Study on Dynamics and Stability of Miniature End Mills

Investigation on Surface Finishing of Components Ground with Lapping Kinematics: Lapgrinding Process

Chapter 11: Computer Aided Manufacturing (CAM)

Interest of Multiphysics and Multilevel Simulation Approaches to Enhance the Machining Process

Simulation of Serrated End Milling Using Solid Modeling Techniques

Optimization of Non-Cutting Tool Paths

Optimization of the 2 1/2 D Pocket Machining Using Multiple Tools

Chapter 12: Experimental: Non Conventional Machining

Surface Quality of Cavities Obtained by EDM Process

Development of a Prototype of Electrochemical Machining

Influence of Correlation between Electrical Discharge Machining Parameters with the Formation of Surface Defect’s in Products Machined by EDM

Finite Element Modeling of Microstructural Changes in Hard Turning

Keywords Index

Authors Index

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