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

Abstract

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.

Authors:
; ORCiD logo
Publication Date:
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE)
OSTI Identifier:
1510343
Grant/Contract Number:  
EE0008605
Resource Type:
Published Article
Journal Name:
Journal of Manufacturing and Materials Processing
Additional Journal Information:
Journal Name: Journal of Manufacturing and Materials Processing Journal Volume: 3 Journal Issue: 2; Journal ID: ISSN 2504-4494
Publisher:
MDPI AG
Country of Publication:
Country unknown/Code not available
Language:
English

Citation Formats

Takabi, Behrouz, and Tai, Bruce L. Finite Element Modeling of Orthogonal Machining of Brittle Materials Using an Embedded Cohesive Element Mesh. Country unknown/Code not available: N. p., 2019. Web. doi:10.3390/jmmp3020036.
Takabi, Behrouz, & Tai, Bruce L. Finite Element Modeling of Orthogonal Machining of Brittle Materials Using an Embedded Cohesive Element Mesh. Country unknown/Code not available. doi:10.3390/jmmp3020036.
Takabi, Behrouz, and Tai, Bruce L. Thu . "Finite Element Modeling of Orthogonal Machining of Brittle Materials Using an Embedded Cohesive Element Mesh". Country unknown/Code not available. doi:10.3390/jmmp3020036.
@article{osti_1510343,
title = {Finite Element Modeling of Orthogonal Machining of Brittle Materials Using an Embedded Cohesive Element Mesh},
author = {Takabi, Behrouz and Tai, Bruce L.},
abstractNote = {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.},
doi = {10.3390/jmmp3020036},
journal = {Journal of Manufacturing and Materials Processing},
number = 2,
volume = 3,
place = {Country unknown/Code not available},
year = {2019},
month = {5}
}

Journal Article:
Free Publicly Available Full Text
Publisher's Version of Record
DOI: 10.3390/jmmp3020036

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