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

Takabi, Behrouz; Tai, Bruce L.

doi:10.3390/jmmp3020036

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

Journal Article · Thu May 02 00:00:00 EDT 2019 · Journal of Manufacturing and Materials Processing

DOI:https://doi.org/10.3390/jmmp3020036· OSTI ID:1510343

Takabi, Behrouz;

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.

View Journal Article

Cite

Export

Save

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE)

Grant/Contract Number:: EE0008605

OSTI ID:: 1510343

Journal Information:: Journal of Manufacturing and Materials Processing, Journal Name: Journal of Manufacturing and Materials Processing Vol. 3 Journal Issue: 2; ISSN 2504-4494

Publisher:: MDPI AGCopyright Statement

Country of Publication:: Switzerland

Language:: English

References (18)

A study of energy dissipating mechanisms in orthogonal cutting of UD-CFRP composites Yan, Xiaoye; Reiner, Johannes; Bacca, Mattia Composite Structures, Vol. 220 https://doi.org/10.1016/j.compstruct.2019.03.090	journal	July 2019
A grain level model for the study of failure initiation and evolution in polycrystalline brittle materials. Part II: Numerical examples Espinosa, Horacio D.; Zavattieri, Pablo D. Mechanics of Materials, Vol. 35, Issue 3-6 https://doi.org/10.1016/S0167-6636(02)00287-9	journal	March 2003
A cutting force model for rotary ultrasonic machining of brittle materials Liu, DeFu; Cong, W. L.; Pei, Z. J. International Journal of Machine Tools and Manufacture, Vol. 52, Issue 1 https://doi.org/10.1016/j.ijmachtools.2011.09.006	journal	January 2012
Modeling machining of particle-reinforced aluminum-based metal matrix composites using cohesive zone elements Umer, U.; Ashfaq, M.; Qudeiri, J. A. The International Journal of Advanced Manufacturing Technology, Vol. 78, Issue 5-8 https://doi.org/10.1007/s00170-014-6715-5	journal	January 2015
Micro-mechanical modeling of machining of FRP composites – Cutting force analysis Rao, G. Venu Gopala; Mahajan, P.; Bhatnagar, N. Composites Science and Technology, Vol. 67, Issue 3-4 https://doi.org/10.1016/j.compscitech.2006.08.010	journal	March 2007
Machining FEM model of long fiber composites for aeronautical components Santiuste, Carlos; Soldani, Xavier; Miguélez, Maria Henar Composite Structures, Vol. 92, Issue 3 https://doi.org/10.1016/j.compstruct.2009.09.021	journal	February 2010
Prediction of surface generation in microgrinding of ceramic materials by coupled trajectory and finite element analysis Feng, Jie; Chen, Peng; Ni, Jun Finite Elements in Analysis and Design, Vol. 57 https://doi.org/10.1016/j.finel.2012.03.002	journal	September 2012
The influence of Johnson–Cook material constants on finite element simulation of machining of AISI 316L steel Umbrello, D.; M’Saoubi, R.; Outeiro, J. C. International Journal of Machine Tools and Manufacture, Vol. 47, Issue 3-4 https://doi.org/10.1016/j.ijmachtools.2006.06.006	journal	March 2007
An engineering solution for mesh size effects in the simulation of delamination using cohesive zone models Turon, A.; Dávila, C. G.; Camanho, P. P. Engineering Fracture Mechanics, Vol. 74, Issue 10 https://doi.org/10.1016/j.engfracmech.2006.08.025	journal	July 2007
Introduction of a New Dynamic Fracture Toughness Evaluation System Petersen, Dr; Kobayashi, T.; Yamamoto, I. Journal of Testing and Evaluation, Vol. 21, Issue 3 https://doi.org/10.1520/JTE11763J	journal	January 1993
Numerical study of smoothed particle hydrodynamics method in orthogonal cutting simulations – Effects of damage criteria and particle density Takabi, Behrouz; Tajdari, Mahsa; Tai, Bruce L. Journal of Manufacturing Processes, Vol. 30 https://doi.org/10.1016/j.jmapro.2017.10.020	journal	December 2017
Determination of Johnson–Cook parameters from machining simulations Shrot, Aviral; Bäker, Martin Computational Materials Science, Vol. 52, Issue 1 https://doi.org/10.1016/j.commatsci.2011.07.035	journal	February 2012
Evaluation of Ductile Fracture Models in Finite Element Simulation of Metal Cutting Processes Liu, Jian; Bai, Yuanli; Xu, Chengying Journal of Manufacturing Science and Engineering, Vol. 136, Issue 1 https://doi.org/10.1115/1.4025625	journal	November 2013
Multi-scale genome modeling for predicting fracture strength of silicon carbide ceramics Dong, Xiangyang; Shin, Yung C. Computational Materials Science, Vol. 141 https://doi.org/10.1016/j.commatsci.2017.09.012	journal	January 2018
A review of cutting mechanics and modeling techniques for biological materials Takabi, Behrouz; Tai, Bruce L. Medical Engineering & Physics, Vol. 45 https://doi.org/10.1016/j.medengphy.2017.04.004	journal	July 2017
Dynamic fracture toughness of Homalite-100: Dynamic fracture toughness of Homalite-100 determined by T. Kobayashi and Dally, as well as those of Araldite B by Kalthoff, Beinert and Winkler, are compared with those of the authors' previous results. Errors generated through the use of static near-field crack-tip stresses for evaluating dynamic stress-intensity factor are also discussed Kobayashi, A. S.; Mall, S. Experimental Mechanics, Vol. 18, Issue 1 https://doi.org/10.1007/BF02326552	journal	January 1978
Finite Element Modeling of Carbon Fiber Composite Orthogonal Cutting and Drilling Usui, Shuji; Wadell, Jon; Marusich, Troy Procedia CIRP, Vol. 14 https://doi.org/10.1016/j.procir.2014.03.081	journal	January 2014
The Influence of Material Models on Finite Element Simulation of Machining Shi, Jing; Liu, C. Richard Journal of Manufacturing Science and Engineering, Vol. 126, Issue 4 https://doi.org/10.1115/1.1813473	journal	November 2004

Similar Records

Simulations of dynamic crack propagation in brittle materials using nodal cohesive forces and continuum damage mechanics in the distinct element code LDEC

Journal Article · Wed Aug 23 00:00:00 EDT 2006 · International Journal of Fracture · OSTI ID:1510343

Block, G I; Rubin, M B; Morris, J P; +1 more

An analytically enriched finite element method for cohesive crack modeling.

Conference · Thu Apr 01 00:00:00 EDT 2010 · OSTI ID:1510343

Cox, James V

Modeling brittle fracture, slip weakening, and variable friction in geomaterials with an embedded strong discontinuity finite element.

Technical Report · Sun Oct 01 00:00:00 EDT 2006 · OSTI ID:1510343

Regueiro, Richard A; Borja, R I; Foster, C D

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

Citation Formats

References (18)

Similar Records

Related Subjects