In this paper, the effect of four sequential cuts in side milling of Ti6Al4V on chip formation and residual stresses （RS） are investigated using finite element method （FEM）. While the open literature is limited ma...In this paper, the effect of four sequential cuts in side milling of Ti6Al4V on chip formation and residual stresses （RS） are investigated using finite element method （FEM）. While the open literature is limited mainly to the studies of orthogonal sequential cutting with the constant uncut chip thickness greater than 0.01 mm, it is suggested herein to investigate not only the variable uncut chip thickness which characterises the down milling process, but also the uncut chip thickness in the sub-micron range using a finite cutting edge radius. For the resulting ductile machining regime, the characteristics of the chip mor- phology, the force profiles, the plastic deformation and temperature distributions have been analyzed. Furthermore, this study revealed that the RS should be extracted toward the area where the insert exits the workpiece in the FE simulation of the down-milling process. The simulation of a number of sequential cuts due to the consecutive engagements of the insert is required in order to capture the gradual accumulation of the RS before reaching an asymptotic convergence of the RS profile. The predicted RS are in reasonable agreement with the experimental results.展开更多
The chip deformation of titanium alloys is typical shear localization from low cutting speed, which is general phenomenon in machining of difficult to cut material at high cutting speed. This paper investigates the ...The chip deformation of titanium alloys is typical shear localization from low cutting speed, which is general phenomenon in machining of difficult to cut material at high cutting speed. This paper investigates the chip formation process in machining titanium alloys, and puts forward a three stage model describing formation process of shear localized chip. This model explains how the shear localized chip segments initiate, become trapezoid and form serrated chips.展开更多
Numerical simulation is an effective approach in studying cutting mechanism.The widely used methods for cutting simulation include finite element analysis and molecular dynamics.However,there exist some intrinsic shor...Numerical simulation is an effective approach in studying cutting mechanism.The widely used methods for cutting simulation include finite element analysis and molecular dynamics.However,there exist some intrinsic shortcomings when using a mesh-based formulation,and the capable scale of molecular dynamics is extremely small.In contrast,smoothed particle hydrodynamics(SPH)is a candidate to combine the advantages of them.It is a particle method which is suitable for simulating the large deformation process,and is formulated based on continuum mechanics so that large scale problems can be handled in principle.As a result,SPH has also become a main way for the cutting simulation.Since some issues arise while using conventional SPH to handle solid materials,the total Lagrangian smoothed particle hydrodynamics(TLSPH)is developed.But instabilities would still occur during the cutting,which is a critical issue to resolve.This paper studies the effects of TLSPH settings and cutting model parameters on the numerical instability,as well as the chip formation process.Plastic deformation,stress field and cutting forces are analyzed as well.It shows that the hourglass coefficient,critical pairwise deformation and time step are three important parameters to control the stability of the simulation,and a strategy on how to adjust them is provided.展开更多
The miniaturisation context leads to the rise of micro-machining processes. Micro-milling is one of the most flexible and fast of them. Although it is based on the same principles as macro-cutting, it is not a simple ...The miniaturisation context leads to the rise of micro-machining processes. Micro-milling is one of the most flexible and fast of them. Although it is based on the same principles as macro-cutting, it is not a simple scaling-down of it. This down-sizing involves new phenomena in the chip formation, such as the minimum chip thickness below which no chip is formed. This paper presents a review of the current state of the art in this field from an experimental and a numerical point of view. A 2D finite element model is then developed to study the influence of the depth of cut on the chip formation. After the model validation in macro-cutting, it highlights the phenomena reported in literature and allows to perform a minimum chip thickness estimation.展开更多
Abstract Predictive models for machining operations have been significantly improved through numerous methods in recent decades. This study proposed a 3D finite element modeling （3D FEM） approach for the micro end-m...Abstract Predictive models for machining operations have been significantly improved through numerous methods in recent decades. This study proposed a 3D finite element modeling （3D FEM） approach for the micro end-milling orAl6061-T6. Finite element （FE） simulations were performed under different cutting conditions to obtain realistic numerical predictions of chip flow, burr formation, and cutting forces. FE modeling displayed notable advantages, such as capability to easily handle any type of tool geometry and any side effect on chip formation, including thermal aspect and material property changes. The proposed 3D FE model considers the effects ofmiU helix angle and cutting edge radius on the chip. The prediction capability of the FE model was validated by comparing numerical model and experimental test results. Burr dimension trends were correlated with force profile shapes. However, the FE predictions overestimated the real force magnitude. This overestimation indicates that the model requires further development.展开更多
To benefit tissue removal and postoperative rehabilitation,increased efficiency and accuracy and reduced operating force are strongly required in the osteotomy.A novel elliptical vibration cutting(EVC)has been introdu...To benefit tissue removal and postoperative rehabilitation,increased efficiency and accuracy and reduced operating force are strongly required in the osteotomy.A novel elliptical vibration cutting(EVC)has been introduced for bone cutting compared with conventional cutting(CC)in this paper.With the assistance of high-speed microscope imaging and the dynamometer,the material removals of cortical bone and their cutting forces from two cutting regimes were recorded and analysed comprehensively,which clearly demonstrated the chip morphology improvement and the average cutting force reduction in the EVC process.It also revealed that the elliptical vibration of the cutting tool could promote fracture propagation along the shear direction.These new findings will be of important theoretical and practical values to apply the innovative EVC process to the surgical procedures of the osteotomy.展开更多
Cortical bone is semi-brittle and anisotropic,that brings a challenge to suppress vibration and avoid undesired fracture in precise cutting process in surgeries.In this paper,a novel analytical model is proposed to re...Cortical bone is semi-brittle and anisotropic,that brings a challenge to suppress vibration and avoid undesired fracture in precise cutting process in surgeries.In this paper,a novel analytical model is proposed to represent cortical bone cutting processes.The model is utilized to predict the chip formations,material removal behavior and cracks propagation under varying bone osteon cutting angles and depths.Series of orthogonal cutting experiments were conducted on cortical bone to investigate the impact of bone osteon cutting angle and depth of cut on cutting force,crack initialization and propagation.The observed chip morphology highly agreed with the prediction of chip formation based on the analytical model.The curly,serrated,grainy and powdery chips formed when the cutting angle was set as 0°,60°,90°,and 120°,respectively.Cortical bone were removed dominantly by shearing at a small depth of cut from 10 to 50μm,and by a mixture of pealing,shearing,fracture and crushing at a large depth of cut over 100μm at different bone osteon angles.Moreover,its fracture toughness was calculated based on measured cutting force.It is found that the fluctuation of cutting force is suppressed and the bone material becomes easy to remove,which attributes to lower fracture toughness at bone osteon cutting angle 0°.When the cutting direction develops a certain angle to bone osteon,the fracture toughness increases then the crack propagation is inhibited to some extent and the fluctuation of cutting force comparatively decreases.There is a theoretical and practical significance for tools design and operational parameters choice in surgeries.展开更多
Based on the “principle of minimum energy”, the basic characteristics of non-free cutting are studied; the phenomenon and the nature of chip-ejection interference commonly existing in the cutting process of modern c...Based on the “principle of minimum energy”, the basic characteristics of non-free cutting are studied; the phenomenon and the nature of chip-ejection interference commonly existing in the cutting process of modern cutting tools are explored. A “synthesis method of elementary cutting tools” is suggested for modeling the cutting process of modern complex cutting tools. The general equation governing the chip-ejection motion is deduced. Real examples of non-free cutting are analyzed and the theoretically predicted results are supported by the experimental data or facts. The sufficient and necessary conditions for eliminating chip-ejection interference and for realizing free cutting are given; the idea and the technical approach of “the principle of free cutting” are also discussed, and a feasible way for improving or optimizing the cutting performance of modern cutting tools is, therefore, found.展开更多
文摘In this paper, the effect of four sequential cuts in side milling of Ti6Al4V on chip formation and residual stresses （RS） are investigated using finite element method （FEM）. While the open literature is limited mainly to the studies of orthogonal sequential cutting with the constant uncut chip thickness greater than 0.01 mm, it is suggested herein to investigate not only the variable uncut chip thickness which characterises the down milling process, but also the uncut chip thickness in the sub-micron range using a finite cutting edge radius. For the resulting ductile machining regime, the characteristics of the chip mor- phology, the force profiles, the plastic deformation and temperature distributions have been analyzed. Furthermore, this study revealed that the RS should be extracted toward the area where the insert exits the workpiece in the FE simulation of the down-milling process. The simulation of a number of sequential cuts due to the consecutive engagements of the insert is required in order to capture the gradual accumulation of the RS before reaching an asymptotic convergence of the RS profile. The predicted RS are in reasonable agreement with the experimental results.
文摘The chip deformation of titanium alloys is typical shear localization from low cutting speed, which is general phenomenon in machining of difficult to cut material at high cutting speed. This paper investigates the chip formation process in machining titanium alloys, and puts forward a three stage model describing formation process of shear localized chip. This model explains how the shear localized chip segments initiate, become trapezoid and form serrated chips.
基金supported by the National key Research and Development Program of China(No.2016YFB 1102203)the National Natural Science Foundation of China(No.61635008)the‘111’project by the State Administration of Foreign Experts Affairs and the Ministry of Education of China(Grant No.B07014).
文摘Numerical simulation is an effective approach in studying cutting mechanism.The widely used methods for cutting simulation include finite element analysis and molecular dynamics.However,there exist some intrinsic shortcomings when using a mesh-based formulation,and the capable scale of molecular dynamics is extremely small.In contrast,smoothed particle hydrodynamics(SPH)is a candidate to combine the advantages of them.It is a particle method which is suitable for simulating the large deformation process,and is formulated based on continuum mechanics so that large scale problems can be handled in principle.As a result,SPH has also become a main way for the cutting simulation.Since some issues arise while using conventional SPH to handle solid materials,the total Lagrangian smoothed particle hydrodynamics(TLSPH)is developed.But instabilities would still occur during the cutting,which is a critical issue to resolve.This paper studies the effects of TLSPH settings and cutting model parameters on the numerical instability,as well as the chip formation process.Plastic deformation,stress field and cutting forces are analyzed as well.It shows that the hourglass coefficient,critical pairwise deformation and time step are three important parameters to control the stability of the simulation,and a strategy on how to adjust them is provided.
文摘The miniaturisation context leads to the rise of micro-machining processes. Micro-milling is one of the most flexible and fast of them. Although it is based on the same principles as macro-cutting, it is not a simple scaling-down of it. This down-sizing involves new phenomena in the chip formation, such as the minimum chip thickness below which no chip is formed. This paper presents a review of the current state of the art in this field from an experimental and a numerical point of view. A 2D finite element model is then developed to study the influence of the depth of cut on the chip formation. After the model validation in macro-cutting, it highlights the phenomena reported in literature and allows to perform a minimum chip thickness estimation.
文摘Abstract Predictive models for machining operations have been significantly improved through numerous methods in recent decades. This study proposed a 3D finite element modeling （3D FEM） approach for the micro end-milling orAl6061-T6. Finite element （FE） simulations were performed under different cutting conditions to obtain realistic numerical predictions of chip flow, burr formation, and cutting forces. FE modeling displayed notable advantages, such as capability to easily handle any type of tool geometry and any side effect on chip formation, including thermal aspect and material property changes. The proposed 3D FE model considers the effects ofmiU helix angle and cutting edge radius on the chip. The prediction capability of the FE model was validated by comparing numerical model and experimental test results. Burr dimension trends were correlated with force profile shapes. However, the FE predictions overestimated the real force magnitude. This overestimation indicates that the model requires further development.
基金Supported by National Natural Science Foundation of China (Grant Nos.52005199 and 42241149)Shenzhen Fundamental Research Program (Grant Nos.JCYJ20200109150425085 and JCYJ20220818102601004)+2 种基金Shenzhen Science and Technology Program (Grant Nos.JSGG20201103100001004 and JSGG20220831105800001)Research Development Program of China (Grant No.2022YFB4602502)Knowledge Innovation Program of Wuhan-Basic Research (Grant No.2022010801010203)。
文摘To benefit tissue removal and postoperative rehabilitation,increased efficiency and accuracy and reduced operating force are strongly required in the osteotomy.A novel elliptical vibration cutting(EVC)has been introduced for bone cutting compared with conventional cutting(CC)in this paper.With the assistance of high-speed microscope imaging and the dynamometer,the material removals of cortical bone and their cutting forces from two cutting regimes were recorded and analysed comprehensively,which clearly demonstrated the chip morphology improvement and the average cutting force reduction in the EVC process.It also revealed that the elliptical vibration of the cutting tool could promote fracture propagation along the shear direction.These new findings will be of important theoretical and practical values to apply the innovative EVC process to the surgical procedures of the osteotomy.
基金China Scholarship Council,the National Natural Science Foundation of China(Grant No.52075161)Hunan Provincial Natural Science Foundation of China(Grant No.2022JJ40486)Changsha Municipal Natural Science Foundation of China(Grant No.2022cskj017).
文摘Cortical bone is semi-brittle and anisotropic,that brings a challenge to suppress vibration and avoid undesired fracture in precise cutting process in surgeries.In this paper,a novel analytical model is proposed to represent cortical bone cutting processes.The model is utilized to predict the chip formations,material removal behavior and cracks propagation under varying bone osteon cutting angles and depths.Series of orthogonal cutting experiments were conducted on cortical bone to investigate the impact of bone osteon cutting angle and depth of cut on cutting force,crack initialization and propagation.The observed chip morphology highly agreed with the prediction of chip formation based on the analytical model.The curly,serrated,grainy and powdery chips formed when the cutting angle was set as 0°,60°,90°,and 120°,respectively.Cortical bone were removed dominantly by shearing at a small depth of cut from 10 to 50μm,and by a mixture of pealing,shearing,fracture and crushing at a large depth of cut over 100μm at different bone osteon angles.Moreover,its fracture toughness was calculated based on measured cutting force.It is found that the fluctuation of cutting force is suppressed and the bone material becomes easy to remove,which attributes to lower fracture toughness at bone osteon cutting angle 0°.When the cutting direction develops a certain angle to bone osteon,the fracture toughness increases then the crack propagation is inhibited to some extent and the fluctuation of cutting force comparatively decreases.There is a theoretical and practical significance for tools design and operational parameters choice in surgeries.
基金Project supported by the National Natural Science Foundation of China (Grant No. 59675058).
文摘Based on the “principle of minimum energy”, the basic characteristics of non-free cutting are studied; the phenomenon and the nature of chip-ejection interference commonly existing in the cutting process of modern cutting tools are explored. A “synthesis method of elementary cutting tools” is suggested for modeling the cutting process of modern complex cutting tools. The general equation governing the chip-ejection motion is deduced. Real examples of non-free cutting are analyzed and the theoretically predicted results are supported by the experimental data or facts. The sufficient and necessary conditions for eliminating chip-ejection interference and for realizing free cutting are given; the idea and the technical approach of “the principle of free cutting” are also discussed, and a feasible way for improving or optimizing the cutting performance of modern cutting tools is, therefore, found.
