This work is focused on the study of orthogonal cutting of long fiber composites. A model based in finite element was developed. The mechanisms of chip formation of Glass and Carbon Fiber Reinforced Polymer (FRP) composites were analyzed. Significant differences were observed when comparing machining induced damage predicted with the model for both materials. While damage extended widely ahead the interface and beneath the tool tip in the case of GFRP, damage was located in a much smaller zone in the case CFRP. The fiber orientation influences both the mechanism of chip formation and the induced subsurface damage.

This work is focused on the combined study of the evolution of tool wear, quality of machined holes and surface integrity of work-piece, in the dry drilling of alloy Ti-6Al-4V. Tool wear was studied with optical microscope and SEM-EDS techniques. The quality of machined holes was estimated in terms of geometrical accuracy and burr formation. Surface integrity involves the study of surface roughness, metallurgical alterations and microhardness tests. The end of tool life was reached because of catastrophic failure of the drill, but no significant progressive wear in cutting zone was observed previously. High hole quality was observed even near tool catastrophic failure, evaluated from the point of view of dimensions, surface roughness and burr height. However, microhardness measurements and SEM-EDS analysis of work-piece showed important microstructural changes related with a loss of mechanical properties. Depending on the application of the machined component, the state of the work-piece could be more restrictive than the tool wear, and the end of tool life should be established from the point of view of controlled damage in a work-piece.

This paper focuses on the effect of the drill geometry on the drilling of woven Carbon Fiber Reinforced Polymer composite (CFRPs). Although different geometrical effects can be considered in drilling CFRPs, the present work focuses on the influence of point angle and wear because they are the important factors influencing hole quality and machining forces. Surface quality was evaluated in terms of delamination and superficial defects. Three different point angles were tested representative of the geometries commonly used in the industry. Two wear modes were considered, being representative of the wear patterns commonly observed when drilling CFRPs: flank wear and honed cutting edge. It was found that the crossed influence of the point angle and wear were significant to the thrust force. Delamination at the hole entry and exit showed opposite trends with the change of geometry. Also, cutting parameters were checked showing the feed’s dominant influence on surface damage.

This paper focuses on the analysis of tool wear mechanisms in finishing turning of Inconel 718, one of the most used Ni alloys, both in wet and dry cutting. Cemented carbides, ceramics and CBN tools are suitable for machining Ni alloys; coated carbide tools are competitive for machining operations of Ni alloys and widely used in industry. Commercial coated carbide tools (multilayer coating TiAl/ TiAlN recommended for machining Ni alloys) were studied in this work. The feasibility of two inserts tested for dry cutting of Inconel 718 has been shown in the work. Experimental test were performed in order to analyze wear patterns evolution. It was found great influence of side cutting edge angle in tool wear mode.

CFRPs Drilling Delamination ModelingDelamination is one of the undesired effects of machining using non appropriate cutting parameters or worn drill. Finite element modeling of drilling of Carbon Fiber Reinforced Polymer (CFRP) composites is an interesting tool for damage prediction. Recently, complete modeling of the process including the rotatory movement of the drill, penetration in the composite plate and element erosion has been developed in the scientific literature. Computational cost of these complex models is a great disadvantage when comparing them with simplified models that consider the drill acting like a punch that pierces the laminate. In this paper both complete and simplified models were developed and compared in terms of delamination prediction. The simplified model, presenting reduced computational cost, slightly overestimates the delamination factor when compared with the complex model. The influence on delamination of thrust force, clamping area at the bottom surface of the laminate and the stacking sequence is studied using the simplified model.

The first objective of this paper is to analyze the influence of mesh size and shape in finite element modeling of composite cutting. Also the influence of the level of energy needed to reach complete breakage of the element is considered. The statement of this level of energy is crucial to simulate the material behavior. On the other hand geometrical characteristics of the tool have significant influence on machining processes. The second objective of the present work is to advance in the knowledge concerning tool geometry and its effect in composite cutting.A two-dimensional finite element model of orthogonal cutting has been developed and validated for Glass LFRP composite, comparing with experimental results presented in scientific literature. It was demonstrated that both numerical parameters and tool geometry influence the predicted chip morphology and machining induced damage.

The generation of residual stresses in orthogonal machining is analysed by using an Arbitrary Lagrangian Eulerian (ALE) finite element approach. It is shown that a substantial level of tensile residual stresses can be obtained in the vicinity of the machined surface without any contribution of thermal effects. This motivates the development of a parametric study to analyse the effects of the thermomechanical coupling parameters on residual stresses. The roles of thermal expansion, of thermal softening and of the Taylor-Quinney coefficient (controlling the heat generated by plastic flow) are considered separately. The influence of friction is also analysed by assuming dry cutting conditions and a Coulomb friction law. The friction coefficient has a complex effect by controlling heat generation (frictional heating) along the tool rake and clearance faces and the propensity for the chip to stick to the tool. Geometrical effects such as the tool rake angle and the tool edge radius are also discussed.

This paper is focused on the behavior of boring bars with a passive dynamic vibration absorber (DVA) for chatter suppression. The boring bar was modeled as a cantilever Euler-Bernoulli beam and only its first mode of vibration was considered. The stability of the two-degree-of-freedom model was analyzed constructing the stability diagram, dependent on the bar characteristics and on the absorber parameters (mass, stiffness, damping, and position). Two analytical approaches for tuning the absorber parameters were compared. The selection criterion consisted on the maximization of the minimum values of the stability-lobes diagram. Subsequent analysis performed in this work, allowed formulating of new analytical expressions for the tuning frequency improving the behavior of the system against chatter.