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Advances in Modelling of Machining Operations
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Advances in Modelling of Machining Operations

A special issue of Journal of Manufacturing and Materials Processing (ISSN 2504-4494).

Deadline for manuscript submissions: closed (31 August 2021) | Viewed by 30701

Special Issue Editors

Prof. Dr. Abdelhadi Moufki

E-Mail Website
Guest Editor
University of Lorraine, LEM3 CNRS-UMR 7239, 7 rue Félix Savart, 57070 Metz, France
Interests: manufacturing processes (machining, SLM, FSW); vibration in machining processes; mechanics of materials (multiscale modeling and simulation); tribology (sticking-sliding contact, thermomechanical friction law, frictional heat partition...); wear (diffusion, etc.); multiscale modeling and simulation; analytical approach; numerical modeling (FEM, SPH, etc.); hybrid approach "analytical-FE"
Prof. Dr. Jose Carlos Martins Outeiro

E-Mail Website
Guest Editor
Department of Mechanical Engineering and Engineering Science, Charlotte, University of North Carolina (UNC) at Charlotte, Charlotte, NC, USA
Interests: surface integrity and functional performance and life of components; manufacturing process modeling and simulation; development of new constitutive models for manufacturing process simulation; sustainable manufacturing solutions (cryogenic machining, MQL, etc.); development of new (hybrid) manufacturing processes; advanced materials processing; digital twin

Special Issue Information

Dear Colleagues,

In order to improve manufacturing productivity, product quality, and to reduce cost, the use of cutting process simulations represents a real alternative to the empirical experimental approaches (trial/error) often used in the industry. The introduction of new products requires the development of an appropriate production solution. Process models can be particularly important for use in process planning systems for machining processes. Predicting how the material removal affects tool and workpieces in machining processes is an efficient way to assist manufacturing industries to optimize the cutting conditions and to guide the tool design.

Modeling of tool–chip interaction allows analyzing the coupling between the work material behavior, the tribological conditions at the tool–workpiece interfaces, and the process parameters (cutting speed, tool geometry, tool coatings, material removal rate, etc.). The aim is to offer a good estimation of several thermomechanical parameters: temperatures, strains, strain-rates, stresses, tool wear, surface and subsurface integrity, burr formation, etc. To achieve this goal, advanced predictive and multiphysics models need to be developed. Cutting models can be based on different approaches: analytical, numerical, mechanistic, experimental, and hybrid modelling. Another important aspect of machining modelling is process stability and chatter. In industry, to avoid chatter vibration, the material removal rate is often reduced. Consequently, prediction and control of chatter require modeling of coupling between the thermomechanical process of chip formation and different sources of cutting instability as regenerative and frictional chatters. This Special Issue will cover recent advances in modeling of machining operations.

The topics include but are not limited to:

  • Multiphysics modelling of machining process: turning, milling, drilling, broaching, grinding, etc.
  • Thermomechanical process of chip formation
  • Tribology of machining process
  • Thermo-viscoplastic behavior
  • Tool wear: diffusion, abrasive, etc.
  • Surface and subsurface integrity
  • Burr formation
  • Cutting process stability
  • Optimization of the machining process: cutting conditions and tool geometry
  • Machining of traditional and new advanced materials (composite, ceramics, honeycomb, bulk metallic glasses, additive manufacture, etc.)
  • Micro-machining modelling
  • Machining-assisted process: cryogenic-assisted machining; ultrasonic vibration-assisted machining, laser-assisted machining, etc.

Prof. Dr. Abdelhadi Moufki
Dr. José Outeiro
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Journal of Manufacturing and Materials Processing is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 1800 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

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Further information on MDPI's Special Issue polices can be found here.

Published Papers (8 papers)

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Research

22 pages, 6086 KiB  
Article
Modelling and Optimization of Machining of Ti-6Al-4V Titanium Alloy Using Machine Learning and Design of Experiments Methods
by José Outeiro, Wenyu Cheng, Francisco Chinesta and Amine Ammar
J. Manuf. Mater. Process. 2022, 6(3), 58; https://doi.org/10.3390/jmmp6030058 - 27 May 2022
Cited by 16 | Viewed by 5211
Abstract
Ti-6Al-4V titanium is considered a difficult-to-cut material used in critical applications in the aerospace industry requiring high reliability levels. An appropriate selection of cutting conditions can improve the machinability of this alloy and the surface integrity of the machined surface, including the generation [...] Read more.
Ti-6Al-4V titanium is considered a difficult-to-cut material used in critical applications in the aerospace industry requiring high reliability levels. An appropriate selection of cutting conditions can improve the machinability of this alloy and the surface integrity of the machined surface, including the generation of compressive residual stresses. In this paper, orthogonal cutting tests of Ti-6Al-4V titanium were performed using coated and uncoated tungsten carbide tools. Suitable design of experiments (DOE) was used to investigate the influence of the cutting conditions (cutting speed Vc, uncut chip thickness h, tool rake angle γn, and the cutting edge radius rn) on the forces, chip compression ratio, and residual stresses. Due to the time consumed and the high cost of the residual stress measurements, they were only measured for selected cutting conditions of the DOE. Then, the machine learning method based on mathematical regression analysis was applied to predict the residual stresses for other cutting conditions of the DOE. Finally, the optimal cutting conditions that minimize the machining outcomes were determined. The results showed that when increasing the compressive residual stresses at the machined surface by 40%, the rake angle should be increased from negative (−6°) to positive (5°), the cutting edge radius should be doubled (from 16 µm to 30 µm), and the cutting speed should be reduced by 67% (from 60 to 20 m/min). Full article
(This article belongs to the Special Issue Advances in Modelling of Machining Operations)
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31 pages, 10406 KiB  
Article
A Methodology for Tribo-Mechanical Characterization of Metallic Alloys under Extreme Loading and Temperature Conditions Typical of Metal Cutting Processes
by Afonso V. L. Gregório, Tiago E. F. Silva, Alcino P. Reis, Abílio M. P. de Jesus and Pedro A. R. Rosa
J. Manuf. Mater. Process. 2022, 6(2), 46; https://doi.org/10.3390/jmmp6020046 - 13 Apr 2022
Cited by 3 | Viewed by 2986
Abstract
The present paper proposes a combined tribo-mechanical methodology for assessing friction under conditions representative of metal cutting, without resorting to machining process monitoring. The purpose is to withdraw the size effect’s contribution due to tool edge radius to the well-known overestimation of the [...] Read more.
The present paper proposes a combined tribo-mechanical methodology for assessing friction under conditions representative of metal cutting, without resorting to machining process monitoring. The purpose is to withdraw the size effect’s contribution due to tool edge radius to the well-known overestimation of the friction coefficient. Comparative numerical analysis of several tribological tests led us to conclude that the ring compression test is one of the most suitable for reproducing the frictional conditions at the chip–tool interface. Two distinct metallic alloys were selected to demonstrate the application of the proposed methodology (UNS L51120 lead alloy and 18Ni300 maraging steel in conventional and additively manufactured conditions). The results help to better explain the influences of process parameters on the friction coefficient value under high temperature and high strain rate conditions. Results showed a typical increase in the coefficient of friction of up to 20% due to both temperature and strain rate parameters for 18Ni300. The results are of interest because they allow considering potential sources of error in the numerical simulation of metal cutting when the same friction coefficient value is considered for a wide range of cutting parameters. Full article
(This article belongs to the Special Issue Advances in Modelling of Machining Operations)
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16 pages, 6074 KiB  
Article
Investigation of Gyroscopic Effect on the Stability of High Speed Micromilling via Bifurcation Analysis
by Rinku K. Mittal and Ramesh K. Singh
J. Manuf. Mater. Process. 2021, 5(4), 130; https://doi.org/10.3390/jmmp5040130 - 2 Dec 2021
Cited by 3 | Viewed by 2638
Abstract
Catastrophic tool failure due to the low flexural stiffness of the micro-tool is a major concern for micromanufacturing industries. This issue can be addressed using high rotational speed, but the gyroscopic couple becomes prominent at high rotational speeds for micro-tools affecting the dynamic [...] Read more.
Catastrophic tool failure due to the low flexural stiffness of the micro-tool is a major concern for micromanufacturing industries. This issue can be addressed using high rotational speed, but the gyroscopic couple becomes prominent at high rotational speeds for micro-tools affecting the dynamic stability of the process. This study uses the multiple degrees of freedom (MDOF) model of the cutting tool to investigate the gyroscopic effect in machining. Hopf bifurcation theory is used to understand the long-term dynamic behavior of the system. A numerical scheme based on the linear multistep method is used to solve the time-periodic delay differential equations. The stability limits have been predicted as a function of the spindle speed. Higher tool deflections occur at higher spindle speeds. Stability lobe diagram shows the conservative limits at high rotational speeds for the MDOF model. The predicted stability limits show good agreement with the experimental limits, especially at high rotational speeds. Full article
(This article belongs to the Special Issue Advances in Modelling of Machining Operations)
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21 pages, 40851 KiB  
Article
Minimisation of Pose-Dependent Regenerative Vibrations for 5-Axis Milling Operations
by Ines Wilck, Andreas Wirtz, Torben Merhofe, Dirk Biermann and Petra Wiederkehr
J. Manuf. Mater. Process. 2021, 5(3), 99; https://doi.org/10.3390/jmmp5030099 - 10 Sep 2021
Cited by 3 | Viewed by 2750
Abstract
The machining of free-formed surfaces, e.g., dies or moulds, is often affected by tool vibrations, which can affect the quality of the workpiece surface. Furthermore, in 5-axis milling, the dynamic properties of the system consisting of the tool, spindle and machine tool can [...] Read more.
The machining of free-formed surfaces, e.g., dies or moulds, is often affected by tool vibrations, which can affect the quality of the workpiece surface. Furthermore, in 5-axis milling, the dynamic properties of the system consisting of the tool, spindle and machine tool can vary depending on the tool pose. In this paper, a simulation-based methodology for optimising the tool orientation, i.e., tilt and lead angle of simultaneous 5-axis milling processes, is presented. For this purpose, a path finding algorithm was used to identify process configurations, that minimise tool vibrations based on pre-calculated simulation results, which were organised using graph theory. In addition, the acceleration behaviour of the feed drives, which limits the ability of adjusting the tool orientation with a high adaption frequency, as well as potential collisions of the tool, tool chuck and spindle with the workpiece were considered during the optimisation procedure. Full article
(This article belongs to the Special Issue Advances in Modelling of Machining Operations)
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22 pages, 36132 KiB  
Article
Influence of Constitutive Models and the Choice of the Parameters on FE Simulation of Ti6Al4V Orthogonal Cutting Process for Different Uncut Chip Thicknesses
by Nithyaraaj Kugalur Palanisamy, Edouard Rivière Lorphèvre, Pedro-José Arrazola and François Ducobu
J. Manuf. Mater. Process. 2021, 5(2), 56; https://doi.org/10.3390/jmmp5020056 - 29 May 2021
Cited by 5 | Viewed by 3426
Abstract
The constitutive model and its pertinent set of parameters are important input data in finite element modeling to define the behavior of Ti6Al4V during machining process. The present work focusses on comparing different constitutive models and the parameters sets available in literatures and [...] Read more.
The constitutive model and its pertinent set of parameters are important input data in finite element modeling to define the behavior of Ti6Al4V during machining process. The present work focusses on comparing different constitutive models and the parameters sets available in literatures and investigating the quality of the predictions when varying uncut chip thickness (40 µm, 60 µm, 100 µm and 280 µm). In addition, temperature-dependent strain hardening factor along with strain softening phenomenon based reconstructed material model is proposed. The results from the numerical simulations are compared with experimental results available in literature. The comparison shows that the force values are highly influenced by constitutive models and the choice of parameters sets, whereas the chip morphologies are mainly influenced by the uncut chip thickness and constitutive models. This work justifies the need for an appropriate set of parameters and constitutive model that replicate the machining behavior of Ti6Al4V alloy for different cutting conditions. Full article
(This article belongs to the Special Issue Advances in Modelling of Machining Operations)
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12 pages, 3077 KiB  
Article
Dexel-Based Simulation of Directed Energy Deposition Additive Manufacturing
by Volker Böß, Berend Denkena, Marc-André Dittrich, Talash Malek and Sven Friebe
J. Manuf. Mater. Process. 2021, 5(1), 9; https://doi.org/10.3390/jmmp5010009 - 11 Jan 2021
Cited by 7 | Viewed by 4516
Abstract
Additive manufacturing is typically a flexible alternative to conventional manufacturing processes. However, manufacturing costs increase due to the effort required to experimentally determine optimum process parameters for customized products or small batches. Therefore, simulation models are needed in order to reduce the amount [...] Read more.
Additive manufacturing is typically a flexible alternative to conventional manufacturing processes. However, manufacturing costs increase due to the effort required to experimentally determine optimum process parameters for customized products or small batches. Therefore, simulation models are needed in order to reduce the amount of effort necessary for experimental testing. For this purpose, a novel technological simulation method for directed energy deposition additive manufacturing is presented here. The Dexel-based simulation allows modeling of additive manufacturing of varying geometric shapes by considering multi-axis machine tool kinematics and local process conditions. The simulation approach can be combined with the simulation of subtractive processes, which enables integrated digital process chains. Full article
(This article belongs to the Special Issue Advances in Modelling of Machining Operations)
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20 pages, 4429 KiB  
Article
Prediction of Shearing and Ploughing Constants in Milling of Inconel 718
by Chi-Jen Lin, Yu-Ting Lui, Yu-Fu Lin, Hsian-Bing Wang, Steven Y. Liang and Jiunn-Jyh Junz Wang
J. Manuf. Mater. Process. 2021, 5(1), 8; https://doi.org/10.3390/jmmp5010008 - 11 Jan 2021
Cited by 8 | Viewed by 3322
Abstract
The present study proposes an integrated prediction model for both shearing and ploughing constants for the peripheral milling of Inconel 718 by using a preidentified mean normal friction coefficient. An equation is presented for the identification of normal mean friction angle of oblique [...] Read more.
The present study proposes an integrated prediction model for both shearing and ploughing constants for the peripheral milling of Inconel 718 by using a preidentified mean normal friction coefficient. An equation is presented for the identification of normal mean friction angle of oblique cutting in milling. A simplified oblique cutting model is adopted for obtaining the shear strain and shearing constants for a tool of given helix angle, radial rake angle, and honed edge radius. The shearing and ploughing constants predicted from analytical model using the Merchant’s shear angle formula and the shear flow stress from the selected Johnson–Cook material law are shown to be consistent with the experimental results. The experimentally identified normal friction angles and shearing and edge ploughing constants for the Inconel 718 milling process are demonstrated to have approximately constant values irrespective of the average chip thickness. Moreover, the predicted forces obtained in milling aged Inconel 718 alloy are in good agreement with the experimental force measurements reported in the literature. Without considering the thermal–mechanical coupling effect in the material law, the presented model is demonstrated to work well for milling of both annealed and aged Inconel 718. Full article
(This article belongs to the Special Issue Advances in Modelling of Machining Operations)
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25 pages, 2212 KiB  
Article
Partition of Primary Shear Plane Heat in Orthogonal Metal Cutting
by Lars Langenhorst, Jens Sölter and Sven Kuschel
J. Manuf. Mater. Process. 2020, 4(3), 82; https://doi.org/10.3390/jmmp4030082 - 13 Aug 2020
Cited by 6 | Viewed by 3803
Abstract
When assessing the effect of metal cutting processes on the resulting surface layer, the heat generated in the chip formation zone that is transferred into the workpiece is of major concern. Models have been developed to estimate temperature distributions in machining processes. However, [...] Read more.
When assessing the effect of metal cutting processes on the resulting surface layer, the heat generated in the chip formation zone that is transferred into the workpiece is of major concern. Models have been developed to estimate temperature distributions in machining processes. However, most of them need information on the heat partition as input for the calculations. Based on analytical and numerical models, it is possible to determine the fraction of shear plane heat transferred into the workpiece for orthogonal cutting conditions. In the present work, these models were utilized to gain information on the significant influencing factors on heat partition, based on orthogonal cutting experiments, experimental results from the literature, and a purely model-based approach. It could be shown that the heat partition does not solely depend on the cutting velocity, the uncut chip thickness, and the thermal diffusivity—combined in the dimensionless thermal number—but the shear angle also has to be taken into account, as already proposed by some researchers. Furthermore, developed numerical models show that a more realistic representation of the process kinematics, e.g., regarding chip flow and temperature-dependent material properties, do not have a relevant impact on the heat partition. Nevertheless, the models still assume an idealized orthogonal cutting process and comparison to experimental-based findings on heat partition indicates a significant influence of the cutting edge radius and the friction on the flank face of the tool. Full article
(This article belongs to the Special Issue Advances in Modelling of Machining Operations)
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