Inverse Identification of Constitutive Model for GH4198 Based on Genetic-Particle Swarm Algorithm.

A precise Johnson-Cook (J-C) constitutive model is the foundation for precise calculation of finite-element simulation. In order to obtain the J-C constitutive model accurately for a new cast and forged alloy GH4198, an inverse identification of J-C constitutive model was proposed based on a genetic-particle swarm algorithm. Firstly, a quasi-static tensile test at different strain rates was conducted to determine the initial yield strength A, strain hardening coefficient B, and work hardening exponent n for the material's J-C model. Secondly, a new method for orthogonal cutting model was constructed based on the unequal division shear theory and considering the influence of tool edge radius. In order to obtain the strain-rate strengthening coefficient C and thermal softening coefficient m, an orthogonal cutting experiment was conducted. Finally, in order to validate the precision of the constitutive model, an orthogonal cutting thermo-mechanical coupling simulation model was established. Meanwhile, the sensitivity of J-C constitutive model parameters on simulation results was analyzed. The results indicate that the parameter m significantly affects chip morphology, and that the parameter C has a notable impact on the cutting force. This study addressed the issue of missing constitutive parameters for GH4198 and provided a theoretical reference for the optimization and identification of constitutive models for other aerospace materials.

The Influence of Osteon Orientation on Surface Topography Parameters after Machining of Cortical Bone Tissue.

Mechanical processing of cortical bone tissue is one of the most common surgical procedures. A critical issue accompanying this processing is the condition of the surface layer, which can stimulate tissue growth and serve as a drug carrier. A comparison of the surface condition before and after orthogonal and abrasive processing was conducted to validate the influence of bone tissue's processing mechanism and orthotropic properties on the surface topography. A cutting tool with a defined geometry and a custom-made abrasive tool was used. The bone samples were cut in three directions, depending on the orientation of the osteons. The cutting forces, acoustic emission, and surface topography were measured. The level of isotropy and the topography of the grooves showed statistical differences relative to the anisotropy directions. After orthogonal processing, the surface topography parameter Ra was determined from 1.38 ± 0.17 µm to 2.82 ± 0.32. In the case of abrasive processing, no correlation was found between the orientation of osteons and topographical properties. The average groove density for abrasive machining was below 1004 ± 0.7, and for orthogonal, it was above 1156 ± 58. Due to the positive properties of the developed bone surface, it is advisable to cut in the transverse direction and parallel to the axis of the osteons.

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.

Chip Formation and Orthogonal Cutting Optimisation of Unidirectional Carbon Fibre Composites.

This study presents a thorough experimental investigation utilising the design of experiments and analysis of variance (ANOVA) to examine the impact of machining process parameters on chip formation mechanisms, machining forces, workpiece surface integrity, and damage resulting from the orthogonal cutting of unidirectional CFRP. The study identified the mechanisms behind chip formation and found it to significantly impact the workpiece orientation of fibre and the tool's cutting angle, resulting in increased fibre bounceback at larger fibre orientation angles and when using smaller rake angle tools. Increasing the depth of cut and fibre orientation angle results in an increased damage depth, while using higher rake angles reduces it. An analytical model based on response surface analysis for predicting machining forces, damage, surface roughness, and bounceback was also developed. The ANOVA results indicate that fibre orientation is the most significant factor in machining CFRP, while cutting speed is insignificant. Increasing fibre orientation angle and depth leads to deeper damage, while larger tool rake angles reduce damage. Machining workpieces with 0° fibre orientation angle results in the least subsurface damage, and surface roughness is unaffected by the tool rake angle for fibre orientations between 0° to 90° but worsens for angles greater than 90°. Optimisation of cutting parameters was subsequently carried out to improve machined workpiece surface quality and reduce forces. The experimental results showed that negative rake angle and cutting at moderately low speeds (366 mm/min) are the optimal conditions for machining laminates with a fibre angle of θ = 45°. On the other hand, for composite materials with fibre angles of θ = 90° and θ = 135°, it is recommended to use a high positive rake angle and cutting speeds.

Orthogonal cutting simulation of EN AW 6082 T6 alloy using a coupled Eulerian-Lagrangian approach.

The latest trends in machining research show that great efforts are being made to simulate machining processes. This paper presents the results of cutting force, feed force and temperatures when the orthogonal cutting of EN AW 6082 T6 alloy. Appropriate material model and damage model were investigated in order to perform finite element simulation with Coupled Eulerian-Lagrangian (CEL) approach. In the next step, simulations were designed based on the input parameters. The size of element in the x-direction (2 µm-10 µm), size of element in y-direction (2 µm-10 µm) and width of the workpiece (2 µm-100 µm) are considered as controllable variables The Genetic Algorithm was used to identify the optimal process parameters by which the minimum value of cutting force error, the minimum value of feed force error and minimum simulation time will be achieved. The optimal combination of the process parameters is size of elements at x-direction 8 µm, y-direction 10 µm and width of workpiece 84 µm. By utilizing the optimal input parameters cutting force error was reduced from 6.5% to 1.07% and feed force error was reduced from 6.15% to 3.12%. The results showed that the optimum size and orientation of the finite element mesh can significantly reduce the error in the prediction of cutting forces and reduce processing simulation time. In addition, it was concluded that with the CEL approach, temperatures in the cutting zone can be successfully predicted.

An Ordinary State-Based Peridynamic Model of Unidirectional Carbon Fiber Reinforced Polymer Material in the Cutting Process.

Due to the complexity of the composite structure, analyzing the material failure process of carbon fiber reinforced polymers (CFRP) is fairly difficult, particularly for the machining process. Peridynamic theory, a new branch of solid mechanics, is a useful tool for dealing with discontinuities. This study presents an ordinary state-based peridynamic (OSB-PD) model for unidirectional CFRP material in the cutting process. In this model, angle tolerance is used to overcome the fiber angle limitation in a classical OSB-PD laminate method, and the short-range force approach is utilized to simulate the contact of the cutting tool and workpiece. The effectiveness of the supplied models is validated by tension and cutting tests. Finally, it can be indicated that the OSB-PD model is capable of predicting machined surface damage and cutting force, based on the comparison of simulation and experimental data.

Prediction of Cutting Force and Chip Formation from the True Stress-Strain Relation Using an Explicit FEM for Polymer Machining.

In the present work, an explicit finite element (FE) model was developed for predicting cutting forces and chip morphologies of polymers from the true stress-strain curve. A dual fracture process was used to simulate the cutting chip formation, incorporating both the shear damage failure criterion and the yield failure criterion, and considering the strain rate effect based on the Johnson-Cook formulation. The frictional behaviour between the cutting tool and specimen was defined by Coulomb's law. Further, the estimated cutting forces and chip thicknesses at different nominal cutting depths were utilized to determine the fracture toughness of the polymer, using an existing mechanics method. It was found that the fracture toughness, cutting forces, and chip morphologies predicted by the FE model were consistent with the experimental results, which proved that the present FE model could effectively reflect the cutting process. In addition, a parametrical analysis was performed to investigate the effects of cutting depth, rake angle, and friction coefficient on the cutting force and chip formation, which found that, among these parameters, the friction coefficient had the greatest effect on cutting force.

Temperature Distribution Simulation, Prediction and Sensitivity Analysis of Orthogonal Cutting of Cortical Bone.

Bone cutting plays an important role in spine surgical operations. The power devices with high speed employing in bone cutting usually leads to high cutting temperature of the bone tissue. This high temperature control is important in improving cutting surface quality and optimizing the cutting parameters. In this paper, the bone-cutting model was appropriately simplified for finite element (FE) based modeling of 2D orthogonal cutting to discuss the change law of cutting temperature of cortical bones for cervical vertebra, and to study the orthogonal cutting mechanism of the anisotropic cortical bone, a 3D FE simulation model had been also established in which longitudinal, vertical, and transversal cutting types were accomplished to investigate the effect of osteons orientation. Secondly, this response surface method was used to regress the simulation results, and establishes the prediction model of maximum temperature on cutting depth, cutting speed, and feed speed. Then, the Sobol method was used to analyze the sensitivity of the milling temperature prediction mathematical model parameters, in order to clarify and quantitatively analyze the influence of input milling parameters on the output milling temperature. Finally, the cutting temperatures obtained with the simulations were compared with the corresponding experimental results obtained from the bone milling tests. This study verifies the influence of key variables and the cutting parameters on thermo mechanical behavior of the bone cutting. The obtained cutting temperature distribution for the bone surfaces could be employed to establish a theoretical foundation for research on thermal damage control of bone tissues.

A Numerical Model for Predicting the Effect of Tool Nose Radius on Machining Process Performance during Orthogonal Cutting of AISI 1045 Steel.

This paper presents the development of a numerical model for predicting and studying the effects of tool nose geometries and its interactions with cutting parameters during orthogonal cutting of AISI 1045 steel. The process performance characteristics studied were cutting temperature, effective stress, cutting forces and tool wear. The cutting simulations were done using the commercial DEFORM-2D R V 11.3 software, based on the finite element method (FEM). The cutting tool used had a round nose with various nose radii (0.01-0.9 mm), while the machining parameters tested were the feed rate (0.1-0.3 mm/rev), the cutting speed (100-500 m/min) and the rake angle (-5° to +10°). The interactions between the tool nose radius and the cutting parameters (speed, feed) were found to affect mostly the cutting stress and, slightly, the tool wear rate. These interactions did not much influence the cutting temperature, that was found to be high when the tool nose radius and/or the cutting speed were high. The maximum temperature was found to occur at the middle of the tool-chip contact length and at the interaction of nose radius and flank face of the tool. Except for some fluctuations, there was no significant difference in tool wear rate between small and large nose radius scales.

Influence of Machining Parameters on Cutting and Chip-Formation Process during Cortical Bone Orthogonal Machining.

Cortical bone machining is commonly used in craniofacial surgery. The shaping of bone surfaces requires a precise determination of the process's complexity due to the cutting tool's defined or undefined geometry. Therefore, research was carried out to assess the impact of the rake angle (γ), clearance angle and depth of cut (d) on the cortical bone machining process. Analysis was carried out based on the orthogonal cutting in three directions. The cutting tool shape was simplified, and the cutting forces and the chip-formation process were monitored. The highest values of the resultant cutting force and shear force were recorded for γ < 0. The specific cutting force decreases with the increase of d. Cutting in the transverse direction is characterized by the highest values of resultant cutting force and shear force. The coefficient of friction depends primarily on the d and takes a constant value or increases with the increase of γ. The tests showed that the chips are formed in the entire range of d ≥ 0.5 µm and create regular shapes for d ≥ 10 µm. The research novelty confirms that even negative cutting angles guarantee controlled cutting and can find wider application in surgical procedures.

Bone Abrasive Machining: Influence of Tool Geometry and Cortical Bone Anisotropic Structure on Crack Propagation.

The abrasive machining of cortical tissue is used in many arthroplasties and craniofacial surgery procedures. However, this method requires further research due to the processes' complexity and the tissue's composite structure. Therefore, studies were carried out to assess the impact of grid geometry and the anisotropic structure of bone tissue on the cutting process and crack propagation. The analysis was performed based on an orthogonal cutting in three directions. The grain shape has been simplified, and the cutting forces, crack path and surface quality were monitored. The results indicate that a depth of cut at 100−25 µm allows the most accurate cutting control. A transverse cutting direction results in the greatest surface irregularity: Iz = 17.7%, Vvc = 3.29 mL/m2 and df = 5.22 µm and generates the most uncontrolled cracks. Maximum fracture force values of FF > 80 N were generated for d = 175 µm. For d < 5 µm, no cracks or only slight penetration occurs. A positive γ provides greater repeatability and crack control. Negative γ generates penetrating cracks and uncontrolled material damage. The individual types of cracks have a characteristic course of changes in Fx. The clearance angle did not affect the crack propagation.

Approximately Model of the Maximum Temperature on the Chip Surface.

This article presents an approximately model that allows for the determination of the maximum temperature of the chip surface in dry orthogonal turning. The mathematical formula describing the maximum temperature of the chip surface was formulated based on experimental data. The experiments were carried out for orthogonal cutting of austenitic steel AISI 321 with flat rake face carbide inserts that were made of tungsten carbide H10F, both uncoated and coated, with coatings of varied arrangement. Thermographic images of the cutting zone were used to verify the correctness of the approximately model. The obtained results show good agreement between the modelling results and experimental studies. The discrepancy of the maximum temperature values of the top surface of the chip does not exceed 6.4%.

Low and High Speed Orthogonal Cutting of AA6061-T6 under Dry and Flood-Coolant Modes: Tool Wear and Residual Stress Measurements and Predictions.

The present research work aimed to study the effects of cutting environments and conditions on tool wear and residual stresses induced by orthogonal cutting of AA6061-T6. Cutting environments included dry- and flood-coolant modes and cutting conditions consisted of cutting speed and feed rate. A 2D finite element (FE) model was developed to predict tool wear and residual stresses and was validated by experimental measurements including machining forces, tool wear, and residual stresses. This was obtained by exploring various magnitudes of the shear friction factor and heat transfer coefficient and choosing proper coefficients using the calibration of the predicted results with the measured ones. The experimental results showed that the effect of cutting environment including dry and flood-coolant modes was negligible on machining forces. The experimental investigation also demonstrated that increasing feed rate raised machining forces, tool wear and residual stresses in both cutting environments. Low Speed Cutting (LSC) led to the highest value of tool wear and High Speed Cutting (HSC) provided the lowest values of resultant machining forces and residual stresses in both modes. Flood-coolant mode reduced tool wear and slightly decreased tensile residual stresses in comparison with dry mode. As a result, low feed rate and high-speed cutting under flood-coolant mode were proposed in order to improve tool wear and residual stress in orthogonal cutting of AA6061-T6.

Investigation of process parameters in orthogonal cutting using finite element approaches.

The cutting force in orthogonal cutting of steel AISI 1045 was predicted by applying 2D finite element analysis (FEA) using two methods; (i) Lagrangian (LAG) and (ii) Arbitrary Lagrangian Eulerian (ALE). Johnson-Cook (J-C) models were used for defining plastic and failure properties of simulated materials. The predicted force was validated experimentally by using dynamometer. Comparison held between the simulation methods and experimental work in terms of results accuracy, reading stability, and chip morphology. Furthermore, this study adopted new modeling idea to control the excessive distortion of mesh elements along chip separation line by defining nearly zero damage criterion for these elements. The results demonstrated that LAG and ALE methods could predict the cutting force but with different accuracy, as LAG and ALE results deviated from experimental results with minimum error percentage 3.6% and 0.14% respectively. As well, ALE method showed stable force readings and continues smooth chip during simulation, while LAG method showed unstable force readings and discontinuous realistic chip.

An investigation of force components in orthogonal cutting of medical grade cobalt-chromium alloy (ASTM F1537).

An ageing population, increased physical activity and obesity are identified as lifestyle changes that are contributing to the ongoing growth in the use of in-vivo prosthetics for total hip and knee arthroplasty. Cobalt-chromium-molybdenum (Co-Cr-Mo) alloys, due to their mechanical properties and excellent biocompatibility, qualify as a class of materials that meet the stringent functional requirements of these devices. To cost effectively assure the required dimensional and geometric tolerances, manufacturers rely on high-precision machining. However, a comprehensive literature review has shown that there has been limited research into the fundamental mechanisms in mechanical cutting of these alloys. This article reports on the determination of the basic cutting-force coefficients in orthogonal cutting of medical grade Co-Cr-Mo alloy ASTM F1537 over an extended range of cutting speeds ([Formula: see text]) and levels of undeformed chip thickness ([Formula: see text]). A detailed characterisation of the segmented chip morphology over this range is also reported, allowing for an estimation of the shear plane angle and, overall, providing a basis for macro-mechanic modelling of more complex cutting processes. The results are compared with a baseline medical grade titanium alloy, Ti-6Al-4V ASTM F136, and it is shown that the tangential and thrust-force components generated were, respectively, ≈35% and ≈84% higher, depending primarily on undeformed chip thickness but with some influence of the cutting speed.

Investigating bone chip formation in craniotomy.

In a craniotomy, the milling cutter is one of the most important cutting tools. The operating performance, tool durability and cutting damage to patients are influenced by the tool's sharpness, intensity and structure, whereas the cutting characteristics rely on interactions between the tool and the skull. In this study, an orthogonal cutting experiment during a craniotomy of fresh pig skulls was performed to investigate chip formation on the side cutting and face cutting of the skull using a high-speed camera. The cutting forces with different combinations of cutting parameters, such as the rake angle, clearance angle, depth of cut and cutting speed, were measured. The skull bone microstructure and cutting damage were observed by scanning electron microscope. Cutting models for different cutting approaches and various depths of cut were constructed and analyzed. The study demonstrated that the effects of shearing, tension and extrusion occur during chip formation. Various chip types, such as unit chips, splintering chips and continuous chips, were generated. Continuous pieces of chips, which are advisable for easy removal from the field of operation, were formed at greater depths of cut and tool rake angles greater than 10°. Cutting damage could be relieved with a faster recovery with clearance angles greater than 20°.

Cutting Modeling of Hybrid CFRP/Ti Composite with Induced Damage Analysis.

In hybrid carbon fiber reinforced polymer (CFRP)/Ti machining, the bi-material interface is the weakest region vulnerable to severe damage formation when the tool cutting from one phase to another phase and vice versa. The interface delamination as well as the composite-phase damage is the most serious failure dominating the bi-material machining. In this paper, an original finite element (FE) model was developed to inspect the key mechanisms governing the induced damage formation when cutting this multi-phase material. The hybrid composite model was constructed by establishing three disparate physical constituents, i.e., the Ti phase, the interface, and the CFRP phase. Different constitutive laws and damage criteria were implemented to build up the entire cutting behavior of the bi-material system. The developed orthogonal cutting (OC) model aims to characterize the dynamic mechanisms of interface delamination formation and the affected interface zone (AIZ). Special focus was made on the quantitative analyses of the parametric effects on the interface delamination and composite-phase damage. The numerical results highlighted the pivotal role of AIZ in affecting the formation of interface delamination, and the significant impacts of feed rate and cutting speed on delamination extent and fiber/matrix failure.