Modeling machining of particle-reinforced aluminum-based metal matrix composites using cohesive zone elements

Umer, Usama; Ashfaq, Mohammad; Qudeiri, Jaber Abu; Hussein, H.M.A.; Danish, Syed Noman

doi:10.1007/s00170-014-6715-5

Cited by 59 publications

(21 citation statements)

References 29 publications

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“…To address this issue, Ghandehariun et al [13] developed a micro-mechanical finite element model of MMC cutting which simulated of the behavior of all phases of the composite, namely, matrix, particle, and particle-matrix interface. Unlike the previous models, such as the model presented in [14], their model was capable of being utilized for analysis of all the interactions between the cutting tool and particles.…”

Section: Introductionmentioning

confidence: 99%

On tool–workpiece interactions during machining metal matrix composites: investigation of the effect of cutting speed

Ghandehariun

Kishawy

Umer

et al. 2015

Int J Adv Manuf Technol

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Metal matrix composites (MMCs) are widely employed in many industrial applications due to their excellent strength and wear characteristics. In order to overcome the challenges faced during machining MMCs, knowledge regarding machinability of MMCs is considered to be an asset. This paper contributes to this field through development of a novel micromechanical finite element model of the process. The developed model includes simulation of all phases of MMC workpiece and is employed for investigation of the effect of cutting speed on MMC machining process. Verification of the model predictions is achieved through comparison with the experimentally measured data. The presented model sheds light on the effect of cutting speed on the change in MMC behavior during machining and provides a significant contribution to the knowledge of MMC machining.

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Section: Introductionmentioning

confidence: 99%

On tool–workpiece interactions during machining metal matrix composites: investigation of the effect of cutting speed

Ghandehariun

Kishawy

Umer

et al. 2015

Int J Adv Manuf Technol

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“…In spite of the extensive research regarding machining MMCs [2][3][4][5][6][7], very few analytical models for analysis of the process exist. Among these analytical models, the basic energy-based model [8] and the mechanistic models [9,10] have gained popularity among researchers.…”

Section: Introductionmentioning

confidence: 99%

Machining metal matrix composites: novel analytical force model

Ghandehariun

Hussein

Kishawy

2015

Int J Adv Manuf Technol

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Outstanding mechanical characteristics make metal matrix composites (MMCs) applicable to many industrial applications. However, the very hard reinforcements that provide such remarkable features for MMCs also cause challenges during the machining process. This paper tries to address these challenges through development of a novel analytical model for prediction of cutting force during machining these composites. The force model is based on calculation of power consumption in different parts of the cutting system. The model considers the plastic deformations, different types of friction at various interfaces and debonding and fracture of reinforcements. The cutting force values predicted by the model are compared with experimental values for various MMCs at different cutting conditions. The close agreement between the results verifies the ability of the model to provide accurate estimation of the cutting force during machining MMCs.

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“…Machining of brittle materials such as ceramics, rocks, composites, and bones is common in aerospace/automotive industries and the medical field [1]. Although efforts [2][3][4][5][6] have been made to model machining of fiber-reinforced composite materials for predicting brittle failure, there is not a generalized method that can successfully and efficiently emulate the physics behind brittle cutting-the rapid and randomized crack initiation and propagation upon tool-workpiece contact. Unlike ductile material cutting, which is dominated by shear deformation across the shear plane, brittle material cutting is driven by fractures.…”

Section: Introductionmentioning

confidence: 99%

“…They used a 2D plane strain model and zero-thickness cohesive elements to enable fiber detachment when the interfacial energy exceeds the threshold defined by an exponential traction-displacement relationship. Umer et al [3] used CZ-FEM to simulate metal matrix composite machining. They modeled the orthogonal machining of SiC particle-reinforced aluminum-based metal matrix composites by placing CZ elements between the particles and the matrix.…”

Section: Introductionmentioning

confidence: 99%

Finite Element Modeling of Orthogonal Machining of Brittle Materials Using an Embedded Cohesive Element Mesh

Takabi

Tai

2019

JMMP

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Machining of brittle materials is common in the manufacturing industry, but few modeling techniques are available to predict materials’ behavior in response to the cutting tool. The paper presents a fracture-based finite element model, named embedded cohesive zone–finite element method (ECZ–FEM). In ECZ–FEM, a network of cohesive zone (CZ) elements are embedded in the material body with regular elements to capture multiple randomized cracks during a cutting process. The CZ element is defined by the fracture energy and a scaling factor to control material ductility and chip behavior. The model is validated by an experimental study in terms of chip formation and cutting force with two different brittle materials and depths of cut. The results show that ECZ–FEM can capture various chip forms, such as dusty debris, irregular chips, and unstable crack propagation seen in the experimental cases. For the cutting force, the model can predict the relative difference among the experimental cases, but the force value is higher by 30–50%. The ECZ–FEM has demonstrated the feasibility of brittle cutting simulation with some limitations applied.

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Modeling machining of particle-reinforced aluminum-based metal matrix composites using cohesive zone elements

Cited by 59 publications

References 29 publications

On tool–workpiece interactions during machining metal matrix composites: investigation of the effect of cutting speed

On tool–workpiece interactions during machining metal matrix composites: investigation of the effect of cutting speed

Machining metal matrix composites: novel analytical force model

Finite Element Modeling of Orthogonal Machining of Brittle Materials Using an Embedded Cohesive Element Mesh

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