Numerical and experimental study of dry cutting for an aeronautic aluminium alloy (A2024-T351)

Mabrouki, Tarek; Girardin, François; Asad, Muhammad; Rigal, Jean-François

doi:10.1016/j.ijmachtools.2008.03.013

Cited by 268 publications

(172 citation statements)

References 16 publications

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“…As illustrated in Fig. 4a, the periodic microwaves distribute on the machined surface uniformly for FM, as numerically predicted by Mabrouki et al [31]. For the small CEF in HSEM, i.e., χ = 0.32, the periodic microwaves still emerge on the machined surface (Fig.…”

Section: Methodssupporting

confidence: 80%

Enhancing surface integrity by high-speed extrusion machining

Liu

Cai

Shang

et al. 2016

Int J Adv Manuf Technol

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High-speed machining (HSM) is an advanced machining technology to form components. However, the poor surface integrity tends to appear due to chip flow instability in HSM. It is found that the surface integrity results from the competition of shear deformation instability between in primary shear zone (PSZ) and in separating shear zone (SSZ). To improve the surface integrity of machined components, the systematic high-speed extrusion machining (HSEM) experiments of magnesium alloy AZ31B with different constraint extrusion factors (CEFs) were carried out. The instability of shear deformation in PSZ is suppressed, and the microwaves on machined surface disappear when CEF is equal to or larger than a certain value. The measurements of the machined surface show that an improvement of surface integrity is achieved if CEF exceeds a certain value. The theoretical model for HSEM was established to elucidate the critical CEF. The underlying physics of surface integrity in HSEM is further revealed. The experimental results verify the validity of the theoretical model.

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Section: Methodssupporting

confidence: 80%

Enhancing surface integrity by high-speed extrusion machining

Liu

Cai

Shang

et al. 2016

Int J Adv Manuf Technol

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“…Mabrouki et al [2] investigated the characteristics of chip morphology and chip microstructures during cutting operation under high loading. Mabrouki et al [18] also investigated the dry cutting of an aeronautic aluminium alloy and developed the numerical model based on the Johnson-Cook law incorporating with material damage evolution by using a fracture energy model. The feed rate and cutting velocity were used as the simulation variables.…”

Section: Chip Formation Mechanism Using Finite Element Simulationmentioning

confidence: 99%

“…The JC damage parameters used for the present study are given in Table 2. The temperature factor D 5 is null which means that the temperature has no effect on the damage initiation during the cutting of the aluminium alloy A2024-T351 [18]. …”

Section: Damage Initiationmentioning

confidence: 99%

“…In addition, K IC is not a constant property; it is varying depending on the fracture mode of material including the micro-crack formation, element dislocation, and subsequent crack growth along the fracture line. Mabrouki et al [18] the employed fracture energy method into the FEM model by using K IC values measured at a nominal size to estimate the fracture energy required as a damage evolution criterion. G f values defined in [18] is 16711 N/m for the opening mode of fracture and 8251 N/m for the shearing mode of fracture, which are estimated from Eq.…”

Section: Damage Evolution Based On Fracture Energy Dissipationmentioning

confidence: 99%

“…Mabrouki et al [18] the employed fracture energy method into the FEM model by using K IC values measured at a nominal size to estimate the fracture energy required as a damage evolution criterion. G f values defined in [18] is 16711 N/m for the opening mode of fracture and 8251 N/m for the shearing mode of fracture, which are estimated from Eq. (9).…”

Section: Damage Evolution Based On Fracture Energy Dissipationmentioning

confidence: 99%

See 2 more Smart Citations

Chip Formation Mechanism Using Finite Element Simulation

Öpöz¹,

Chen²

2016

SV-JME

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Opoz, TT and Chen, X Chip formation mechanism using finite element simulation http://researchonline.ljmu.ac.uk/4059/ Article LJMU has developed LJMU Research Online for users to access the research output of the University more effectively. Copyright © and Moral Rights for the papers on this site are retained by the individual authors and/or other copyright owners. Users may download and/or print one copy of any article(s) in LJMU Research Online to facilitate their private study or for non-commercial research. You may not engage in further distribution of the material or use it for any profit-making activities or any commercial gain.The version presented here may differ from the published version or from the version of the record. Please see the repository URL above for details on accessing the published version and note that access may require a subscription. INTRODUCTIONChip formation during machining processes is a material removal process in which the materials are removed from the workpiece in the form of numerous tiny chips. To understand chip formation regarding the chip types, shapes as well as the stress/strain distribution would help the prediction of cutting force and thermal behaviour to avoid unexpected vibration and thermal damage. To do this, the finite element models of machining processes are very popular for simulating chip formation [1] to [15]. The reason is to minimize labour cost and save time by reducing expensive experimental tests. In contrast, the estimation of some physical phenomena such as the distribution of stress and strain under machining conditions is quite difficult to accomplish with experimental tests. Finite element method (FEM) provides a convenient method to visualise material performance under different machining conditions. Therefore, the prediction of chip types and chip shapes under different operating conditions is one of the significant benefits provided by FEM simulations. In metal cutting processes, often three types of chip formation occur (continuous chips, serrated chips, and discontinuous chips), which are produced as a result of the cutting deformation mechanism, operating parameters, and workpiece mechanical and thermal properties. The continuous chip is often considered to be an ideal chip that generates stable cutting forces; however, it is not desired for automated machining because the continuous chips may obstruct the machining process, which may lead to unpredictable damage on the machined surface, cutting tool or machine tool. To minimize these problems, serrated chips that are easier to break and remove are preferred during machining [1] and [2], so, predicting the cutting conditions which lead to a serrated chip has become increasingly important.In some literature, serrated chips are called sawtooth shape or continuous segmented chips. Increased segmentation on continuous chips eventually leads to serrated chips. It is common knowledge that segmentation during chip formation is triggered by two phenomena: the formation of the adiabatic shear band a...

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