Wear Mechanism of CBN Inserts During Machining of Bimetal Aluminum-grey Cast Iron Engine Block

Malakizadi, Amir; Sadik, Ibrahim; Nyborg, Lars

doi:10.1016/j.procir.2013.06.087

Cited by 25 publications

(13 citation statements)

References 11 publications

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“…In the literature, a relatively limited number of studies are found regarding the machining of objects made of dissimilar materials. In particular, the studies reported in [14][15][16][17][18][19][20][21] are noted. These studies show that the machining of a multi-material object entails some unique properties.…”

Section: Introductionmentioning

confidence: 96%

Machining Forces Due to Turning of Bimetallic Objects Made of Aluminum, Titanium, Cast Iron, and Mild/Stainless Steel

Sharif

2018

JMMP

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This article elucidates the characteristics of machining forces (an important phenomenon by which machining is studied) using three sets of bimetallic specimens made of aluminum–titanium, aluminum–cast iron, and stainless steel–mild steel. The cutting, feed, and thrust forces were recorded for different cutting conditions (i.e., different cutting speeds, feeds, and cutting directions). Possibility distributions were used to quantify the uncertainty associated with machining forces, which were helpful in identifying the optimal machining direction. In synopsis, it was found that while machining the steel-based bimetallic specimens, keeping a low feed and high cutting speed is the better option, and the machining operation can be performed in both the hard-to-soft and soft-to-hard material directions, but machining in the soft-to-hard material direction is the better option. On the other hand, very soft materials should not be used in fabricating a bimetallic part because it creates machining problems. Cutting power was estimated using the cutting and feed force signals. Manufacturers who support sustainable product development (including design, manufacturing, and assembly) can benefit from the outcomes of this study because parts/products made of dissimilar materials (or multi-material objects) are better than their mono-material counterparts in terms of sustainability (cost, weight, and CO2 footprint).

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Section: Introductionmentioning

confidence: 96%

Machining Forces Due to Turning of Bimetallic Objects Made of Aluminum, Titanium, Cast Iron, and Mild/Stainless Steel

Sharif

2018

JMMP

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“…In the past, a lot of research work has been carried out to improve the machining performance of cast iron. 4–12 Yigit et al. 4 used the uncoated and coated tools to study the influence of cutting speed on the turning of nodular cast iron.…”

Section: Introductionmentioning

confidence: 99%

Investigation on experiment and simulation of the grinding process of cast iron

Shi

2020

Proceedings of the Institution of Mechanical Engineers, Part C:

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Grinding is used to reduce form error and improve the surface quality of workpiece in metal cutting. To investigate the grinding process of cast iron, a series of grinding tests and simulation of cast iron were carried out. At the same time, the finite element method was used to establish a finite element model to simulate the grinding process of cast iron. In the model, the dynamic effects, thermo-mechanical coupling, Johnson–Cook constitutive model, material damage model, and contact model were taken into account. Then, the grinding process of cast iron was simulated using the established finite element model in the ABAQUS software. Material remove, residual stress, grinding force, and cutting temperature were achieved through the simulation. In addition, the effect of the main grinding parameters (depth of grinding and spindle speed) on residual stress, grinding force, and surface quality in the grinding of cast iron was investigated.

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“…For instance, Filho [12] used the particle swarm optimization algorithm, and Shrot and Bäker [13] utilized a re-identification process of the JC parameters based on Levenberg-Marquardt optimization algorithm. Malakizadi et al [14] combined response surface methodology with Oxley's machining theory for inverse identification of JC parameters. The authors later extended this approach by a re-evaluation of the JC parameters and friction coefficients using finite element (FE) simulations [15].…”

Section: Introductionmentioning

confidence: 99%

A thermomechanically motivated approach for identification of flow stress properties in metal cutting

Erturk

Malakizadi

Larsson

2020

Int J Adv Manuf Technol

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The paper presents a novel thermomechanically coupled distributed primary deformation zone model to assist the inverse identification of Johnson-Cook material parameters to be used for machining simulations. A special feature of the enhanced model is that the assumed stress field is temperature-dependent, where the thermomechanical coupling governs the stress and temperature distributions across the primary shear zone to describe the thermal softening effect. By using stress, strain, strain rate, and temperature distributions from the thermomechanically enhanced model, Johnson-Cook material parameters are calibrated for orthogonal cutting tests of C38, 42CrMo4, and AA6082 materials where continuous chip formation prevails. The performance of the parameters is compared with that of a wider set of cutting tests using finite element simulations. The results show that the thermomechanically motivated model yields closer results to experiments in terms of cutting force and chip thickness (9% and 34% difference, respectively) compared with the original thermally uncoupled model (47% and 92% difference, respectively). Identification of the material parameters by this method focuses directly on the orthogonal cutting test and it does not require many experiments or simulations. In fact, the proposed methodology is computationally robust and cost-efficient which makes it preferable compared with other methods which are more accurate but highly time-consuming.

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Wear Mechanism of CBN Inserts During Machining of Bimetal Aluminum-grey Cast Iron Engine Block

Cited by 25 publications

References 11 publications

Machining Forces Due to Turning of Bimetallic Objects Made of Aluminum, Titanium, Cast Iron, and Mild/Stainless Steel

Machining Forces Due to Turning of Bimetallic Objects Made of Aluminum, Titanium, Cast Iron, and Mild/Stainless Steel

Investigation on experiment and simulation of the grinding process of cast iron

A thermomechanically motivated approach for identification of flow stress properties in metal cutting

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