Finite element modeling of chip separation in machining cellular metals

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.

Analytical design of effective thermal conductivity for fluid-saturated prismatic cellular metal honeycombs

A comparative optimal design of fluid-saturated prismatic cellular metal honeycombs （PCMHs） having different cell shapes is presented for thermal management applications. Based on the periodic topology of each PCMH, a unit cell （UC） for thermal transport analysis was selected to calculate its effective thermal conductivity. Without introducing any empirical coefficient, we modified and extended the analytical model of parallel-series thermal-electric network to a wider porosity range （0.7 ~ 0.98） by considering the effects of two-dimensional local heat conduction in solid ligaments inside each UC. Good agreement was achieved between analytical predictions and numerical simulations based on the method of finite volume. The concept of ligament heat conduction efficiency （LTCE） was proposed to physically explain the mechanisms underlying the effects of ligament configuration on effective thermal conductivity （ETC）. Based upon the proposed theory, a construct strategy was developed for designing the ETC by altering the equivalent interaction angle with the direction of heat flow： relatively small average interaction angle for thermal conduction and relatively large one for thermal insulation.

Production and characterization of high porosity porous Fe?Cr?C alloys by the space holder leaching technique

Spherical carbamide particles were employed to produce porous Fe–Cr–C alloy with high porosity and large aperture via the space-holder leaching technique. A series of porous samples were prepared by regulating the processing parameters, which included the carbamide content and the compaction pressure. The pore characteristics and compression properties of the produced samples were investigated. The samples were characterized by scanning electron microscopy, image analysis, and compression tests. The results showed that the macro-porosity and the mean pore size were in the ranges 40.4%–82.4% and 0.6–1.5 mm, respectively. The compressive strength varied between 25.38 MPa and 127.9 MPa, and was observed to decrease with increasing total porosity.

Dynamic Responses of Cellular Metal-Filled Steel Beam-Column Joint Under Impact Loading

Taking the excellent energy absorption performances of cellular structures into consideration,three beam-column steel joints are proposed to analyze the effect of cellular metallic fillers on impact mechanical responses of beam-column joints.Based on the existing experimental results,the finite element models of the associated joints are established by using finite element method software.The deformation mode,the bearing capacity and energy absorption performance of various joints subjected to impact loadings with the loading velocities from 10 to 100 m/s are analyzed,respectively.The dynamic responses of cellular metal-filled beamcolumn joints are quantitatively analyzed by means of displacements of central region,nominal impacting stress and energy absorption efficiency.The results can be concluded that the filling of cellular filler weakens the stress concentration on joints,alleviates the occurrence of tearing in connection region among column and beam,and reduces the displacement caused by impact loading.Energy absorption efficiency of filled joints subjected to impact loading increases as the impacting velocity increases,and the cellular metallic filler improves their impact resistance of beam-column joints.The energy absorption efficiency of fully filled joints is superior to that of others.This study can provide a reference for steel structural design and post-disaster repair under extreme working conditions.