Modeling and Simulation of Tool Wear During the Cutting Process

Salvatore, Ferdinando; Saad, Salma Mansour; Hamdi, Hédi

doi:10.1016/j.procir.2013.06.107

Cited by 33 publications

(20 citation statements)

References 7 publications

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“…Reference [4] used a modified Bai-Wierzbicki material model for a more accurate prediction of chip formation. New studies are also focused on the numerical simulation of tool wear [28,16,30]. This type of study presents particular challenges due to the complexity of the wear mechanisms.…”

Section: Introductionmentioning

confidence: 99%

Development of a numerical model for the understanding of the chip formation in high-pressure water-jet assisted machining

Ayed¹,

Robert²,

Germain³

et al. 2016

Finite Elements in Analysis and Design

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a b s t r a c tThe aim of this study is to develop a new numerical cutting model that includes fluid structure interaction and to take into account heat transfer between the water-jet, the workpiece and the chip. This has been achieved using a CEL (Coupled-Eulerian-Lagrangian) technique, an algorithm has been developed to ensure heat exchange between the fluid and the structure. This new model allows decoupling of the mechanical and the thermal effects of the water-jet on chip formation and fragmentation. It has been demonstrated that fragmentation of the chip is ensured by the combination of the thermal and the mechanical effects of the water-jet. Moreover, the tool rake temperature is reduced by more than 400°C, the tool/chip contact length is also decreased by about 30%.

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Section: Introductionmentioning

confidence: 99%

Development of a numerical model for the understanding of the chip formation in high-pressure water-jet assisted machining

Ayed¹,

Robert²,

Germain³

et al. 2016

Finite Elements in Analysis and Design

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show abstract

“…This approach is similar to [8] that describes cutting process in turning operation as orthogonal cutting. [9] assuming that the modeled workpiece as the flat surface to machined the cutter moves linearly. Face cutting is often called as facing cutting.…”

Section: Fundamental Of Metal Cutting Processmentioning

confidence: 99%

“…The HSS tool material was simulated where the model used in [6] for analysis bending occurring on material C1060 cutting process under constant conditions. The most of them using FEM 2D to simulate cutting process, 2D ABAQUS/explicit and FEM code Deform-2D being employed [7][8][9][10][11][12][13][14]. FEM simulation of cutting processes has been changed to be an analysis effective method for minimizing the use of experimental work.…”

Section: Introductionmentioning

confidence: 99%

Prediction of 3D chip formation in the facing cutting with lathe machine using FEM

Prasetyo

Tauviqirrahman²,

Rusnaldy³

2016

AIP Conference Proceedings

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“…Inspired by previous works [9,10,11], a new approach called "vertical modelling" is proposed in this paper; to increase machining time simulated (Fig.2) In fact, many calculations are performed successively on a reduced length of the machined surface (1.8 mm). To insure the continuity from one calculation to another, the thermal state in the cutting tool is taken into account.…”

Section: Decreasing Computational Timementioning

confidence: 99%

“…Salvatore et al [10] proposed also a solution to increase the simulated time on ABAQUS©. It is based on partitioning the chip since it can be considered uninteresting for his study that focuses on tool wear estimation.…”

Section: Introductionmentioning

confidence: 99%

A New Procedure to Increase the Orthogonal Cutting Machining Time Simulated

et al. 2015

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Surface integrity is extremely affected by manufacturing processes conditions especially the evolution of cutting tool performance. Many researchers, in steel machining field, focused their works on the elaboration of models predicting tool wear combining both numerical and experimental approaches. Most of published numerical cutting models simulate the chip formation for a few micro to millisecond time periods. For that, all corresponding experimental tests, needed for the model validation, are usually carried-out in special time conditions which is not reflecting industrial situations. Indeed, the latters are characterized by tool wear whose evolution can affect extremely cutting force levels and the final workpiece integrity.In this context, the main purpose of the proposed research work is to develop a FEM model, based on the commercial code ABAQUS©, to simulate wear phenomenon of tool insert in the case of orthogonal cutting operation. The present research exposes a lagrangian approach simulating the chip formation in the case of AISI 4140 machining. A strategy that aims to reach high machining time simulated with moderate computational time is presented. It is based on ensuring the thermal continuity of the tool from one calculation to another. A considerable gain of calculation time is achieved comparing to the most common models developed on ABAQUS©.

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Modeling and Simulation of Tool Wear During the Cutting Process

Cited by 33 publications

References 7 publications

Development of a numerical model for the understanding of the chip formation in high-pressure water-jet assisted machining

Development of a numerical model for the understanding of the chip formation in high-pressure water-jet assisted machining

Prediction of 3D chip formation in the facing cutting with lathe machine using FEM

A New Procedure to Increase the Orthogonal Cutting Machining Time Simulated

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