Högskolan i Skövde

In machining, the heat generated during the process deforms the components and the final shape might not meet specified tolerances. There is therefore a need for a compensation strategy which requires knowledge of the workpiece temperature field and the associated thermal distortions. In this work, a methodology is presented for the determination of the heat load for indexable insert drilling of AISI 4140. Compared to previous research, this work has introduced a varying heat load. The heat load is extracted from thermo-mechanical finite element simulations for different nominal chip thicknesses and cutting speeds using the coupled Eulerian-Lagrangian formulation of an orthogonal turning process. The heat load is then transferred to a simplified 2D axisymmetric heat transfer model where the in-process temperature field in the workpiece is predicted. To verify the methodology, the predicted temperatures are compared to the experimentally measured temperatures for various feed rates. It is found that the model is capable of predicting the workpiece temperatures reasonably well. However, the methodology needs to be further explored to validate its applicability.

Static form errors due to in-process deflections is a major concern in flank milling of thin-walled parts. To increase both productivity and part geometric accuracy, there is a need to predict and control these form errors. In this work, a modelling framework for prediction of the cutting force-induced form errors, or thickness errors, during flank milling of a thin-walled workpiece is proposed. The modelled workpiece geometry is continuously updated to account for material removal and the reduced stiffness matrix is calculated for nodes in the engagement zone. The proposed modelling framework is able to predict the resulting thickness errors for a thin-walled plate which is cut on both sides. Several cutting strategies and cut patterns using constant z-level finishing are studied. The modelling framework is used to investigate the effect of different cut patterns, machining allowance, cutting tools and cutting parameters on the resulting thickness errors. The framework is experimentally validated for various cutting sequences and cutting parameters. The predicted thickness errors closely correspond to the experimental results. It is shown from numerical evaluations that the selection of an appropriate cut pattern is crucial in order to reduce the thickness error. Furthermore, it is shown that an increased machining allowance gives a decreased thickness error for thin-walled plates.

In machining, the heat flow into the workpiece during the cutting process is often a major concern. The temperature rise can lead to substantial residual stresses or elastic in-process deformations which may result in the dimensional tolerance requirements being violated. In the present study a modelling strategy is developed for determination of the heat load during indexable drilling. The heat load on the workpiece is determined from 3D thermomechanical Coupled Eulerian Lagrangian analyses of orthogonal turning for various chip thicknesses and cutting speeds. The determined heat load is then transferred to a 3D transient heat transfer analysis of the indexable drilling process for the determination of the temperature field. Thereby, this modelling technique avoids the complex cutting process that is performed in real cutting simulations and thereby reducing the computational complexity of the problem considerably. The simulated temperatures are compared with experimentally measured temperatures and some conclusions are drawn regarding the modelling approach.

In many industries, indexable insert drills are used to cost effectively produce short holes. However, common problems such as chatter vibrations, premature tool wear and generation of long curly chips that cause poor chip evacuation make optimization of the drilling process challenging and time-consuming. Therefore, robust predictive models of indexable drilling processes are desirable to support the development towards improved tool designs, enhanced cutting processes and increased productivity. This paper presents 3D finite element simulations of indexable drilling of AISI4140 workpieces. The Coupled Eulerian–Lagrangian framework is employed, and the focus is to predict the drilling torque, thrust force, temperature distributions and chip geometries. To reduce the computational effort, the cutting process is modelled separately for the peripheral and the central inserts. The total thrust force and torque are predicted by superposing the predicted result for each insert. Experiments and simulations are conducted at a constant rotational velocity of 2400 rpm and feed rates of 0.13, 0.16 and 0.18 mm/rev. While the predicted torques are in excellent agreement, the thrust forces showed discrepancies of 12 - 20% to the experimental measured data. Effects of the friction modelling on the predicted torque and thrust force are outlined, and possible reasons for the thrust force discrepancies are discussed in the paper. Additionally, the simulations indicate that the tool, chip and the local workpiece temperature distributions are virtually unaffected by the feed rate.

One of the main problems that exists when working with Finite Element Methods (FEM) applied to machining processes is the lack of adequate experimental data for simulating the material properties. Moreover, for damage models based on fracture energy, the correct selection of the energy value is critical for the chip formation process. It is usually difficult to obtain the fracture energy values and requires complex tests. In this work, an analysis of the influence of this fracture energy on the cutting force and the chip generation process has been carried out for different sets of cutting parameters. The aim is to present an empirical relationship, that allows selecting the fracture energy based on the cutting force and cutting parameters. The work is based on a FEM model of an orthogonal turning process for Ti6Al4V alloy using Abaqus/Explicit and the fracture energy empirical relation. This work shows that it is necessary to adjust the fracture energy for each combination of cutting conditions, to be able to fit the experimental results. The cutting force and the chip geometry are analyzed, showing how the developed model adapts to the experimental results. It shows that as the cutting speed and the feed increase, the fracture energy value that best adapts to the model decreases. The evolution shows a more pronounced decrease related to the feed increment and high cutting speed. 

Chip evacuation becomes a relevant factor in the dry machining of aeronautical aluminium alloys, either when they are machined as isotropic material or hybridized with other materials. Chip morphology and geometry highly depend on cutting parameters. Several works can be found in the literature focusing on the analysis of chip morphology of aluminium alloys at high cutting speeds but there is a lack of studies that apply low cutting speeds. FEM simulation may be useful to reduce the experimental time and cost of this kind of analysis. Therefore, in this work, the influence of feed-rate on several chip geometrical parameters (height of peaks, height of valleys and shrinkage factor) of dry turned UNS A92024 alloy has been analysed by FEM simulation. Three different energy fracture modes have been tested as damage evolution criterion, in order to get the mode that better fit the experimental chip morphology. In general, the mixed mode was the fracture energy mode that best suited the chip morphology behaviour, within wider feed-rate range.

Structural tapes provide comparable toughness as structural adhesives at orders of magnitude lower stresses. This is potentially useful to minimize the effects of differences in thermal expansion in the joining of mixed materials. The strength properties are modelled using the cohesive zone model. Thus, a cohesive zone represents the tape, i.e. stresses in the tape are transmitted to the substrates through tractions determined by the separations of the surfaces of substrates. This simplification allows for structural analysis of large complex structures. The relation between the traction and the separation is measured experimentally using methods based on the path independence of the J-integral. Repeated experiments are performed at quasi-static loading. A mixed mode cohesive law is adapted to the experimental data. The law is implemented as a UMAT in Abaqus. Simulations show minor thermal distortions due to thermal loading and substantial structural strength in mechanical loading of a mixed material structure.

Kink-band formation is an important mechanism limiting the compressive strength of high strength composites. A cohesive zone model is used to model the material in a unidirectional carbon fibre composite that forms the kink-band. Equilibrium of configurational forces is used to design and evaluate the experiments. Microscopic studies show that a kink-band is formed with the height of about 200 μm. The corresponding cohesive law has a peak stress of about 1.5 GPa, a compression at failure of about 50 μm and a fracture energy of about 25 kJ/m².

The ability of coupled cohesive laws to conform to the predictions of linear elastic fracturemechanics (LEFM) in the case of small-scale-yielding (SSY) is explored. The study is concerned with cracks in homogeneous orthotropic solids and the results apply also for the case of isotropy. Both potential based and non-potential based cohesive laws are considered. It is shown that the initial stiffnesses of the cohesive law must be matched to the elastic moduli of the orthotropic solid in order to achieve a constant ratio of the cohesive stress components ahead of the crack tip. A simple condition for this is provided. For non potential based laws an additional apparently sufficient condition on the non-linear part of the cohesive law is identified: The traction vector must not change direction if the directionof the separation vector is constant. Fulfillment of this condition provides a uniform local mode mix in the cohesive zone with a value equal to the global mode mix. It is demonstrated that potential based cohesive laws display a varying local mode mix at the crack tip for cases with a mode dependent work of separation. This is identified as acomplicating feature in terms of calibrating the parameters of a cohesive law to experimental data.

Carbon Fibre Reinforced Polymers are widely used in engineering applications where weight saving and high mechanical performance are a key factors. However, an inheren tweakness of laminated CFRP:s is there relatively low resistance to delamination. Therst part of this thesis is devoted to extract cohesive laws associated with delamination.The method is based on fracture mechanical tests and measurement of the displacementeld close to the crack tip. The second part of the thesis is concerned with mixed modecohesive modelling under small scale yielding conditions. Under such loading conditions,a robust cohesive model should conform to Linear Elastic Fracture Mechanics (LEFM). Itis shown that two design rules for mixed mode cohesive laws are sucient to achieve thisproperty. The third part focuses a failure mode entirely dierent from delamination. Theobjective is to determine cohesive laws associated with longitudinal compressive failure.Equilibrium of congurational forces is used for this purpose. Identied congurationalforces are continuously measured by monitoring the displacements eld on the specimen'slateral surface. This allows for identication of the cohesive law.