Application of the Coupled Eulerian-Lagrangian (CEL) method to the modeling of orthogonal cutting

Ducobu, François; Rivière-Lorphèvre, Édouard; Filippi, Enrico

doi:10.1016/j.euromechsol.2016.03.008

Cited by 107 publications

(45 citation statements)

References 43 publications

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“…From the diagram in Figure 6 it can be concluded that the presented Finite Element model was able to represent the chip thickness at higher cutting speed better than at lower cutting speed. In literature Ducobu et al, who compared the CEL and ALE methods when machining Ti6Al4V, also reported that the CEL method overestimates the chip thickness [45]. Figure 7 summaries the measured and with two different DRX models simulated thickness of the White Layer at various cutting conditions (see Table 7).…”

Section: Prediction Of the White Layer Thickness Using Helmholtz Freementioning

confidence: 94%

Modelling of Grain Size Evolution with Different Approaches via FEM When Hard Machining of AISI 4140

Tekkaya

Meurer

Münstermann

2020

Metals

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Thermo-mechanical loads during hard turning lead to the formation of so-called White Layers on the machined surface. Characterized by a very fine microstructure and high hardness, White Layers have a negative effect on the fatigue life of a component. The fundamental mechanism for the White Layer formation is the dynamic recrystallization (DRX). Therefore, in the current work, two different DRX models, Helmholtz free energy and Zener-Hollomon, are implemented into Abaqus/Explicit to predict the thickness of the White Layer when hard turning quenched/tempered AISI 4140 and the results are compared with each other. For the simulation of the machining process a Finite Element Method (FEM) model based on the Coupled-Eulerian-Lagrangian (CEL) method is built up. Although both DRX models achieved a very good match between predicted and measured White Layer thickness and grain size evolution on the workpiece rim zone, the Zener-Hollomon model produced more closer agreement.

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Section: Prediction Of the White Layer Thickness Using Helmholtz Freementioning

confidence: 94%

Modelling of Grain Size Evolution with Different Approaches via FEM When Hard Machining of AISI 4140

Tekkaya

Meurer

Münstermann

2020

Metals

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“…The Johnson–Cook material model was utilised; its flow stress is dependent on strain, strain rate, and temperature [ 19 , 20 , 21 ]. In Johnson–Cook hardening (adapted from [ 22 ]), the static yield stress is defined as

where A is the yield strength, B is the hardening modulus, C is the coefficient of strain rate sensitivity, n is the hardening coefficient, m is the thermal softening coefficient,

where

is the transition temperature and

is the melting temperature,

is the Mises equivalent plastic strain,

is the Mises equivalent plastic strain rate, and

is the reference strain rate [ 23 , 24 ]. Used material constants were obtained from experimental measurements on PUR foam.…”

Section: Materials and Methodsmentioning

confidence: 99%

Application of an Arbitrary Lagrangian–Eulerian Method to Modelling the Machining of Rigid Polyurethane Foam

et al. 2021

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Rigid polyurethane (PUR) foam, which has an extensive range of construction, engineering, and healthcare applications, is commonly used in technical practice. PUR foam is a brittle material, and its mechanical material properties are strongly dependent on temperature and strain rate. Our work aimed to create a robust FE model enabling the simulation of PUR foam machining and verify the results of FE simulations using the experiments’ results. We created a complex FE model using the Arbitrary Lagrangian–Eulerian (ALE) method. In the developed FE model, a constitutive material model was used in which the dependence of the strain rate, damage initiation, damage propagation, and plastic deformation on temperature was implemented. To verify the FE analyses’ results with experimentally measured data, we measured the maximum temperature during PUR foam drilling with different densities (10, 25, and 40 PCF) and at various cutting speeds. The FE models with a constant cutting speed of 500 mm/s and various PUR foam densities led to slightly higher Tmax values, where the differences were 13.1% (10 PCF), 7.0% (25 PCF), and 10.0% (40 PCF). The same situation was observed for the simulation results related to various cutting speeds at a constant PUR foam density of 40 PCF, where the differences were 25.3% (133 mm/s), 10.1% (500 mm/s), and 15.5% (833 mm/s). The presented results show that the ALE method provides a good match with the experimental data and can be used for accurate simulation of rigid PUR foam machining.

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“…The coupled Eulerian–Lagrangian (CEL) method [ 66 , 67 ] was employed for the scratch simulation considering the very complex surface textures and roughness, and the extreme material deformation and damage involved in the scratching, as shown in Figure 4 b. This numerical technology combines the Lagrangian and Eulerian meshes in a single analysis, wherein the material inside the Eulerian region is quantitatively represented by the Eulerian volume fraction (EVF).…”

Section: Textured Surface Model and Scratch Modellingmentioning

confidence: 99%

Finite Element Modelling and Experimental Validation of Scratches on Textured Polymer Surfaces

et al. 2021

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Surface texturing is a common modification method for altering the surface properties of a material. Predicting the response of a textured surface to scratching is significant in surface texturing and material design. In this study, scratches on a thermoplastic material with textured surface are simulated and experimentally tested. The effect of texture on scratch resistance, surface visual appearance, surface deformation and material damage are investigated. Bruise spot scratches on textured surfaces are found at low scratch forces (<3 N) and their size at different scratch forces is approximately the same. There is a critical point between the bruise spot damage and the texture pattern damage caused by continuous scratching. Scratch resistance coefficients and an indentation depth-force pattern are revealed for two textured surfaces. A texture named “Texture CB” exhibits high effectiveness in enhancing scratch visibility resistance and can increase the scratch resistance by more than 40% at low scratch forces. The simulation method and the analysis of the power spectral density of the textured surface enable an accurate prediction of scratches.

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Application of the Coupled Eulerian-Lagrangian (CEL) method to the modeling of orthogonal cutting

Cited by 107 publications

References 43 publications

Modelling of Grain Size Evolution with Different Approaches via FEM When Hard Machining of AISI 4140

Modelling of Grain Size Evolution with Different Approaches via FEM When Hard Machining of AISI 4140

Application of an Arbitrary Lagrangian–Eulerian Method to Modelling the Machining of Rigid Polyurethane Foam

Finite Element Modelling and Experimental Validation of Scratches on Textured Polymer Surfaces

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