Cellular metals and metal foams belong to a young material group. Although it is desired to manufac- ture near-net-shape parts of cellular metals by primary shaping processes, additional secondary machining opera- tio...Cellular metals and metal foams belong to a young material group. Although it is desired to manufac- ture near-net-shape parts of cellular metals by primary shaping processes, additional secondary machining opera- tions are often unavoidable to obtain the required geome- tries and quality demands. Nevertheless, conventional machining of cellular metals leads to undesirable surface damage and poor precision. Furthermore, the chip forma- tion and the mechanism description of the surface damage are still unclear. A mesoscopic finite element model was developed to simulate the chip formation process in machining cellular metals. Experimental data of orthogonal machining tests were used to validate the finite element model. The cutting and thrust forces, as well as the images of the chip formation process of both experiments and simulations were compared and analysed. The model enabled the analysis of the chip formation and the surface defect mechanisms. The rake angle and cutting conditions affected the chip formation process, but the cell arrange- ment was detected as a decisive factor in the chip forma- tion and the resulting surface damage.展开更多
基金the DAAD-Fundayacucho Scholarship Program and the Center for Information Services and High Performance Computing of the TU Dresden for their support
文摘Cellular metals and metal foams belong to a young material group. Although it is desired to manufac- ture near-net-shape parts of cellular metals by primary shaping processes, additional secondary machining opera- tions are often unavoidable to obtain the required geome- tries and quality demands. Nevertheless, conventional machining of cellular metals leads to undesirable surface damage and poor precision. Furthermore, the chip forma- tion and the mechanism description of the surface damage are still unclear. A mesoscopic finite element model was developed to simulate the chip formation process in machining cellular metals. Experimental data of orthogonal machining tests were used to validate the finite element model. The cutting and thrust forces, as well as the images of the chip formation process of both experiments and simulations were compared and analysed. The model enabled the analysis of the chip formation and the surface defect mechanisms. The rake angle and cutting conditions affected the chip formation process, but the cell arrange- ment was detected as a decisive factor in the chip forma- tion and the resulting surface damage.
