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Prediction of cutting force in turning of UD-GFRP using mathematical model and simulated annealing

Meenu GUPTA, Surinder Kumar GILL

《机械工程前沿（英文）》 2012年 第7卷 第4期   页码 417-426 doi: 10.1007/s11465-012-0343-2

摘要：

Glass fiber reinforced plastics (GFRPs) composite is considered to be an alternative to heavy exortic materials. According to the need for accurate machining of composites has increased enormously. During machining, the obtaining cutting force is an important aspect. The present investigation deals with the study and development of a cutting force prediction model for the machining of unidirectional glass fiber reinforced plastics (UD-GFRP) composite using regression modeling and optimization by simulated annealing. The process parameters considered include cutting speed, feed rate and depth of cut. The predicted values radial cutting force model is compared with the experimental values. The results of prediction are quite close with the experimental values. The influences of different parameters in machining of UD-GFRP composite have been analyzed.

关键词： UD-GFRP     ANOVA     radial cutting force     PCD tool     Taguchi method     regression analysis     simulated annealing     multi objective techniques    

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Improved analytical model for residual stress prediction in orthogonal cutting

null

《机械工程前沿（英文）》 2014年 第9卷 第3期   页码 249-256 doi: 10.1007/s11465-014-0310-1

摘要：

The analytical model of residual stress in orthogonal cutting proposed by Jiann is an important tool for residual stress prediction in orthogonal cutting. In application of the model, a problem of low precision of the surface residual stress prediction is found. By theoretical analysis, several shortages of Jiann’s model are picked out, including: inappropriate boundary conditions, unreasonable calculation method of thermal stress, ignorance of stress constraint and cyclic loading algorithm. These shortages may directly lead to the low precision of the surface residual stress prediction. To eliminate these shortages and make the prediction more accurate, an improved model is proposed. In this model, a new contact boundary condition between tool and workpiece is used to make it in accord with the real cutting process; an improved calculation method of thermal stress is adopted; a stress constraint is added according to the volume-constancy of plastic deformation; and the accumulative effect of the stresses during cyclic loading is considered. At last, an experiment for measuring residual stress in cutting AISI 1045 steel is conducted. Also, Jiann’s model and the improved model are simulated under the same conditions with cutting experiment. The comparisons show that the surface residual stresses predicted by the improved model is closer to the experimental results than the results predicted by Jiann’s model.

关键词： residual stress     analytical model     orthogonal cutting     cutting force     cutting temperature    

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Cutting Force Model for a Small-diameter Helical Milling Cutter

LI Xiwen, YANG Shuzi, YANG Mingjin, XIE Shouyong

《机械工程前沿（英文）》 2007年 第2卷 第3期   页码 272-277 doi: 10.1007/s11465-007-0047-1

摘要： In the milling process, the major flank wear land area (two-dimensional measurement for the wear) of a small-diameter milling cutter, as wear standard, can reflect actual changes of the wear land of the cutter. By analyzing the wearing characteristics of the cutter, a cutting force model based on the major flank wear land area is established. Characteristic parameters such as pressure parameter and friction parameter are calculated by substituting tested data into their corresponding equations. The cutting force model for the helical milling cutter is validated by experiments. The computational and experimental results show that the cutting force model is almost consistent with the actual cutting conditions. Thus, the cutting force model established in the research can provide a theoretical foundation for monitoring the condition of a milling process that uses a small-diameter helical milling cutter.

关键词： computational     corresponding     helical milling     theoretical foundation     Characteristic    

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Research on the dynamic mechanical characteristics and turning tool life under the conditions of excessively heavy-duty turning

Genghuang HE, Xianli LIU, Fugang YAN

《机械工程前沿（英文）》 2012年 第7卷 第3期   页码 329-334 doi: 10.1007/s11465-012-0303-x

摘要：

The dynamic mechanical characteristics of excessively heavy-duty cutting were analyzed based on the cutting experiments with 2.25Cr-1Mo-0.25V steel used in hydrogenated cylindrical shells. By investigating the influence of dynamic mechanical characteristics on the tools’ failure in limited heavy-duty cutting processes, the model of dynamic shearing force in the cutting area was established. However, the experimental results showed that the dynamic shear flow stress in the cutting area greatly influenced the tools’ fatigue. The heavy-duty cutting tool was damaged in the form of a shearing fracture. Through a comprehensive analysis of the theory, the critical condition of the tools’ fracture under extreme loading was established.

关键词： extreme loading cutting     shear flow stress     dynamic cutting force     fatigue fracture    

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Prediction of cutting forces in machining of unidirectional glass fiber reinforced plastics composite

Surinder Kumar GILL, Meenu GUPTA, P. S. SATSANGI

《机械工程前沿（英文）》 2013年 第8卷 第2期   页码 187-200 doi: 10.1007/s11465-013-0262-x

摘要：

Machining of plastic materials has become increasingly important in any engineering industry subsequently the prediction of cutting forces. Forces quality has greater influence on components, which are coming in contact with each other. So it becomes necessary to measure and study machined forces and its behavior. In this research work, experimental investigations are conducted to determine the effects of cutting conditions and tool geometry on the cutting forces in the turning of the unidirectional glass fiber reinforced plastics (UD-GFRP) composites. In this experimental study, carbide tool (K10) having different tool nose radius and tool rake angle is used. Experiments are conducted based on the established Taguchi’s technique L18 orthogonal array on a lathe machine. It is found that the depth of cut is the cutting parameter, which has greater influence on cutting forces. The effect of the tool nose radius and tool rake angles on the cutting forces are also considerably significant. Based on statistical analysis, multiple regression model for cutting forces is derived with satisfactory coefficient (R2). This model proved to be highly preferment for predicting cutting forces.

关键词： unidirectional glass fiber reinforced plastics (UD-GFRP) composites     machining     cutting forces (tangential     feed and radial force)     ANOVA     regression modeling     carbide tool (K10)    

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3D finite element prediction of chip flow, burr formation, and cutting forces in micro end-milling of

A. DAVOUDINEJAD, P. PARENTI, M. ANNONI

《机械工程前沿（英文）》 2017年 第12卷 第2期   页码 203-214 doi: 10.1007/s11465-017-0421-6

摘要：

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 of Al6061-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 of mill 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.

关键词： 3D finite element modeling     micro end-milling     cutting force     chip formation     burr formation    

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A hybrid deep learning model for robust prediction of the dimensional accuracy in precision milling of thin-walled structural components

《机械工程前沿（英文）》 2022年 第17卷 第3期 doi: 10.1007/s11465-022-0688-0

摘要： The use of artificial intelligence to process sensor data and predict the dimensional accuracy of machined parts is of great interest to the manufacturing community and can facilitate the intelligent production of many key engineering components. In this study, we develop a predictive model of the dimensional accuracy for precision milling of thin-walled structural components. The aim is to classify three typical features of a structural component—squares, slots, and holes—into various categories based on their dimensional errors (i.e., “high precision,” “pass,” and “unqualified”). Two different types of classification schemes have been considered in this study: those that perform feature extraction by using the convolutional neural networks and those based on an explicit feature extraction procedure. The classification accuracy of the popular machine learning methods has been evaluated in comparison with the proposed deep learning model. Based on the experimental data collected during the milling experiments, the proposed model proved to be capable of predicting dimensional accuracy using cutting parameters (i.e., “static features”) and cutting-force data (i.e., “dynamic features”). The average classification accuracy obtained using the proposed deep learning model was 9.55% higher than the best machine learning algorithm considered in this paper. Moreover, the robustness of the hybrid model has been studied by considering the white Gaussian and coherent noises. Hence, the proposed hybrid model provides an efficient way of fusing different sources of process data and can be adopted for prediction of the machining quality in noisy environments.

关键词： precision milling     dimensional accuracy     cutting force     convolutional neural networks     coherent noise    

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Molecular dynamics modeling of a single diamond abrasive grain in grinding

Angelos P. MARKOPOULOS,Ioannis K. SAVVOPOULOS,Nikolaos E. KARKALOS,Dimitrios E. MANOLAKOS

《机械工程前沿（英文）》 2015年 第10卷 第2期   页码 168-175 doi: 10.1007/s11465-015-0337-y

摘要：

In this paper the nano-metric simulation of grinding of copper with diamond abrasive grains, using the molecular dynamics (MD) method, is considered. An MD model of nano-scale grinding, where a single diamond abrasive grain performs cutting of a copper workpiece, is presented. The Morse potential function is used to simulate the interactions between the atoms involved in the procedure. In the proposed model, the abrasive grain follows a curved path with decreasing depth of cut within the workpiece to simulate the actual material removal process. Three different initial depths of cut, namely 4 ?, 8 ? and 12 ?, are tested, and the influence of the depth of cut on chip formation, cutting forces and workpiece temperatures are thoroughly investigated. The simulation results indicate that with the increase of the initial depth of cut, average cutting forces also increase and therefore the temperatures on the machined surface and within the workpiece increase as well. Furthermore, the effects of the different values of the simulation variables on the chip formation mechanism are studied and discussed. With the appropriate modifications, the proposed model can be used for the simulation of various nano-machining processes and operations, in which continuum mechanics cannot be applied or experimental techniques are subjected to limitations.

关键词： molecular dynamics     abrasive process     chip formation     cutting force     temperature    

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Crystallographic orientation effect on cutting-based single atomic layer removal

Wenkun XIE, Fengzhou FANG

《机械工程前沿（英文）》 2020年 第15卷 第4期   页码 631-644 doi: 10.1007/s11465-020-0599-x

摘要： The ever-increasing requirements for the scalable manufacturing of atomic-scale devices emphasize the significance of developing atomic-scale manufacturing technology. The mechanism of a single atomic layer removal in cutting is the key basic theoretical foundation for atomic-scale mechanical cutting. Material anisotropy is among the key decisive factors that could not be neglected in cutting at such a scale. In the present study, the crystallographic orientation effect on the cutting-based single atomic layer removal of monocrystalline copper is investigated by molecular dynamics simulation. When undeformed chip thickness is in the atomic scale, two kinds of single atomic layer removal mechanisms exist in cutting-based single atomic layer removal, namely, dislocation motion and extrusion, due to the differing atomic structures on different crystallographic planes. On close-packed crystallographic plane, the material removal is dominated by the shear stress-driven dislocation motion, whereas on non-close packed crystallographic planes, extrusion-dominated material removal dominates. To obtain an atomic, defect-free processed surface, the cutting needs to be conducted on the close-packed crystallographic planes of monocrystalline copper.

关键词： ACSM     single atomic layer removal mechanism     crystallographic orientation effect     mechanical cutting     Manufacturing III    

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Modeling of the minimum cutting thickness in micro cutting with consideration of the friction aroundthe cutting zone

Tianfeng ZHOU, Ying WANG, Benshuai RUAN, Zhiqiang LIANG, Xibin WANG

《机械工程前沿（英文）》 2020年 第15卷 第1期   页码 81-88 doi: 10.1007/s11465-019-0561-y

摘要： Friction modeling between the tool and the workpiece plays an important role in predicting the minimum cutting thickness during TC4 micro machining and finite element method (FEM) cutting simulation. In this study, a new three-region friction modeling is proposed to illustrate the material flow mechanism around the friction zone in micro cutting; estimate the stress distributions on the rake, edge, and clearance faces of the tool; and predict the stagnation point location and the minimum cutting thickness. The friction modeling is established by determining the distribution of normal and shear stress. Then, it is applied to calculate the stagnation point location on the edge face and predict the minimum cutting thickness. The stagnation point and the minimum cutting thickness are also observed and illustrated in the FEM simulation. Micro cutting experiments are conducted to validate the accuracy of the friction and the minimum cutting thickness modeling. Comparison results show that the proposed friction model illustrates the relationship between the normal and sheer stress on the tool surface, thereby validating the modeling method of the minimum cutting thickness in micro cutting.

关键词： tool friction     minimum cutting thickness     finite element method     tool edge radius     micro cutting    

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A review on ductile mode cutting of brittle materials

Elijah Kwabena ANTWI, Kui LIU, Hao WANG

《机械工程前沿（英文）》 2018年 第13卷 第2期   页码 251-263 doi: 10.1007/s11465-018-0504-z

摘要：

Brittle materials have been widely employed for industrial applications due to their excellent mecha-nical, optical, physical and chemical properties. But obtaining smooth and damage-free surface on brittle materials by traditional machining methods like grinding, lapping and polishing is very costly and extremely time consuming. Ductile mode cutting is a very promising way to achieve high quality and crack-free surfaces of brittle materials. Thus the study of ductile mode cutting of brittle materials has been attracting more and more efforts. This paper provides an overview of ductile mode cutting of brittle materials including ductile nature and plasticity of brittle materials, cutting mechanism, cutting characteristics, molecular dynamic simulation, critical undeformed chip thickness, brittle-ductile transition, subsurface damage, as well as a detailed discussion of ductile mode cutting enhancement. It is believed that ductile mode cutting of brittle materials could be achieved when both crack-free and no subsurface damage are obtained simultaneously.

关键词： ductile mode cutting     brittle materials     critical undeformed chip thickness     brittle-ductile transition     subsurface damage     molecular dynamic simulation    

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Cutting performance of surgical electrodes by constructing bionic microstriped structures

《机械工程前沿（英文）》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0728-9

摘要： Surgical electrodes rely on thermal effect of high-frequency current and are a widely used medical tool for cutting and coagulating biological tissue. However, tissue adhesion on the electrode surface and thermal injury to adjacent tissue are serious problems in surgery that can affect cutting performance. A bionic microstriped structure mimicking a banana leaf was constructed on the electrode via nanosecond laser surface texturing, followed by silanization treatment, to enhance lyophobicity. The effect of initial, simple grid-textured, and bionic electrodes with different wettabilities on tissue adhesion and thermal injury were investigated using horizontal and vertical cutting modes. Results showed that the bionic electrode with high lyophobicity can effectively reduce tissue adhesion mass and thermal injury depth/area compared with the initial electrode. The formation mechanism of adhered tissue was discussed in terms of morphological features, and the potential mechanism for antiadhesion and heat dissipation of the bionic electrode was revealed. Furthermore, we evaluated the influence of groove depth on tissue adhesion and thermal injury and then verified the antiadhesion stability of the bionic electrode. This study demonstrates a promising approach for improving the cutting performance of surgical electrodes.

关键词： surgical electrodes     tissue adhesion     thermal injury     bionic structures     cutting performance     medical tools    

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Edge preparation methods for cutting tools: a review

《机械工程前沿（英文）》 2023年 第18卷 第4期 doi: 10.1007/s11465-023-0766-y

摘要： Edge preparation can remove cutting edge defects, such as burrs, chippings, and grinding marks, generated in the grinding process and improve the cutting performance and service life of tools. Various edge preparation methods have been proposed for different tool matrix materials, geometries, and application requirements. This study presents a scientific and systematic review of the development of tool edge preparation technology and provides ideas for its future development. First, typical edge characterization methods, which associate the microgeometric characteristics of the cutting edge with cutting performance, are briefly introduced. Then, edge preparation methods for cutting tools, in which materials at the cutting edge area are removed to decrease defects and obtain a suitable microgeometry of the cutting edge for machining, are discussed. New edge preparation methods are explored on the basis of existing processing technologies, and the principles, advantages, and limitations of these methods are systematically summarized and analyzed. Edge preparation methods are classified into two categories: mechanical processing methods and nontraditional processing methods. These methods are compared from the aspects of edge consistency, surface quality, efficiency, processing difficulty, machining cost, and general availability. In this manner, a more intuitive understanding of the characteristics can be gained. Finally, the future development direction of tool edge preparation technology is prospected.

关键词： edge preparation method     preparation principle     cutting edge geometry     edge characterization     tool performance    

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Modeling limit force capacities of high force to volume lead extrusion dampers

《结构与土木工程前沿（英文）》 2021年 第15卷 第3期   页码 609-622 doi: 10.1007/s11709-021-0724-x

摘要： Lead extrusion dampers are supplemental energy-dissipation devices that are used to mitigate seismic structural damage. Small volumetric sizes and high force capacities define high-force-to-volume (HF2V) devices, which can absorb significant response energy without sacrificial damage. However, the design of such devices for specific force capacities has proven difficult based on the complexities of their internal reaction mechanisms, leading to the adoption of empirical approaches. This study developed upper- and lower-bound force capacity estimates from analytical mechanics based on direct and indirect metal extrusion for guiding design. The derived equations are strictly functions of HF2V device geometric parameters, lead material properties, and extrusion mechanics. The upper-bound estimates from direct and indirect extrusion are denoted as (FUB,1, FUB,2) and (FUB,3, FUB,4), respectively, and the lower-bound estimates are denoted as (FLB, FLB,1) based on the combination of extrusion and friction forces. The proposed models were validated by comparing the predicted bounds to experimental force capacity data from 15 experimental HF2V device tests. The experimental device forces all lie above the lower-bound estimates (FLB, FLB,1) and below the upper-bound estimates (FUB,1, FUB,2, FUB,4). Overall, the (FLB, FUB,2) pair provides wider bounds and the (FLB,1, FUB,4/FUB,1) pair provides narrower bounds. The (FLB,1, FUB,1) pair has a mean lower-bound gap of 36%, meaning the lower bound was 74% of the actual device force on average. The mean upper-bound gap was 33%. The bulge area and cylinder diameter of HF2V devices are key parameters affecting device forces. These relatively tight bounds provide useful mechanics-based predictive design guides for ensuring that device forces are within the targeted design range after manufacturing.

关键词： extrusion     lead dampers     upper and lower bound     analytical modelling     limit force    

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Postprocessor development for ultrasonic cutting of honeycomb core curved surface with a straight blade

《机械工程前沿（英文）》 2023年 第18卷 第1期 doi: 10.1007/s11465-022-0729-8

摘要： When ultrasonically cutting honeycomb core curved parts, the tool face of the straight blade must be along the curved surface’s tangent direction at all times to ensure high-quality machining of the curved surface. However, given that the straight blade is a nonstandard tool, the existing computer-aided manufacturing technology cannot directly realize the above action requirement. To solve this problem, this paper proposed an algorithm for extracting a straight blade real-time tool face vector from a 5-axis milling automatically programmed tool location file, which can realize the tool location point and tool axis vector conversion from the flat end mill to the straight blade. At the same time, for the multi-solution problem of the rotation axis, the dependent axis rotation minimization algorithm was introduced, and the spindle rotation algorithm was proposed for the tool edge orientation problem when the straight blade is used to machine the curved part. Finally, on the basis of the MATLAB platform, the dependent axis rotation minimization algorithm and spindle rotation algorithm were integrated and compiled, and the straight blade ultrasonic cutting honeycomb core postprocessor was then developed. The model of the machine tool and the definition of the straight blade were conducted in the VERICUT simulation software, and the simulation machining of the equivalent entity of the honeycomb core can then be realized. The correctness of the numerical control program generated by the postprocessor was verified by machining and accuracy testing of the two designed features. Observation and analysis of the simulation and experiment indicate that the tool pose is the same under each working condition, and the workpieces obtained by machining also meet the corresponding accuracy requirements. Therefore, the postprocessor developed in this paper can be well adapted to the honeycomb core ultrasonic cutting machine tool and realize high-quality and high-efficient machining of honeycomb core composites.

关键词： honeycomb core     straight blade     ultrasonic cutting     tool pose     postprocessor    

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标题 作者 时间 类型 操作

Prediction of cutting force in turning of UD-GFRP using mathematical model and simulated annealing

Meenu GUPTA, Surinder Kumar GILL

期刊论文

Improved analytical model for residual stress prediction in orthogonal cutting

null

期刊论文

Cutting Force Model for a Small-diameter Helical Milling Cutter

LI Xiwen, YANG Shuzi, YANG Mingjin, XIE Shouyong

期刊论文

Research on the dynamic mechanical characteristics and turning tool life under the conditions of excessively heavy-duty turning

Genghuang HE, Xianli LIU, Fugang YAN

期刊论文

Prediction of cutting forces in machining of unidirectional glass fiber reinforced plastics composite

Surinder Kumar GILL, Meenu GUPTA, P. S. SATSANGI

期刊论文

3D finite element prediction of chip flow, burr formation, and cutting forces in micro end-milling of

A. DAVOUDINEJAD, P. PARENTI, M. ANNONI

期刊论文

A hybrid deep learning model for robust prediction of the dimensional accuracy in precision milling of thin-walled structural components

期刊论文

Molecular dynamics modeling of a single diamond abrasive grain in grinding

Angelos P. MARKOPOULOS,Ioannis K. SAVVOPOULOS,Nikolaos E. KARKALOS,Dimitrios E. MANOLAKOS

期刊论文

Crystallographic orientation effect on cutting-based single atomic layer removal

Wenkun XIE, Fengzhou FANG

期刊论文

Modeling of the minimum cutting thickness in micro cutting with consideration of the friction aroundthe cutting zone

Tianfeng ZHOU, Ying WANG, Benshuai RUAN, Zhiqiang LIANG, Xibin WANG

期刊论文

A review on ductile mode cutting of brittle materials

Elijah Kwabena ANTWI, Kui LIU, Hao WANG

期刊论文

Cutting performance of surgical electrodes by constructing bionic microstriped structures

期刊论文

Edge preparation methods for cutting tools: a review

期刊论文

Modeling limit force capacities of high force to volume lead extrusion dampers

期刊论文

Postprocessor development for ultrasonic cutting of honeycomb core curved surface with a straight blade

期刊论文