skip to main content
DOE PAGES title logo U.S. Department of Energy
Office of Scientific and Technical Information

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

Save / Share:

Works referenced in this record:

A study of energy dissipating mechanisms in orthogonal cutting of UD-CFRP composites
journal, July 2019


A grain level model for the study of failure initiation and evolution in polycrystalline brittle materials. Part II: Numerical examples
journal, March 2003


A cutting force model for rotary ultrasonic machining of brittle materials
journal, January 2012


Modeling machining of particle-reinforced aluminum-based metal matrix composites using cohesive zone elements
journal, January 2015

  • Umer, U.; Ashfaq, M.; Qudeiri, J. A.
  • The International Journal of Advanced Manufacturing Technology, Vol. 78, Issue 5-8
  • DOI: 10.1007/s00170-014-6715-5

Micro-mechanical modeling of machining of FRP composites – Cutting force analysis
journal, March 2007


Machining FEM model of long fiber composites for aeronautical components
journal, February 2010


Prediction of surface generation in microgrinding of ceramic materials by coupled trajectory and finite element analysis
journal, September 2012


The influence of Johnson–Cook material constants on finite element simulation of machining of AISI 316L steel
journal, March 2007


An engineering solution for mesh size effects in the simulation of delamination using cohesive zone models
journal, July 2007


Introduction of a New Dynamic Fracture Toughness Evaluation System
journal, January 1993

  • Petersen, Dr; Kobayashi, T.; Yamamoto, I.
  • Journal of Testing and Evaluation, Vol. 21, Issue 3
  • DOI: 10.1520/JTE11763J

Numerical study of smoothed particle hydrodynamics method in orthogonal cutting simulations – Effects of damage criteria and particle density
journal, December 2017


Determination of Johnson–Cook parameters from machining simulations
journal, February 2012


Evaluation of Ductile Fracture Models in Finite Element Simulation of Metal Cutting Processes
journal, November 2013

  • Liu, Jian; Bai, Yuanli; Xu, Chengying
  • Journal of Manufacturing Science and Engineering, Vol. 136, Issue 1
  • DOI: 10.1115/1.4025625

Multi-scale genome modeling for predicting fracture strength of silicon carbide ceramics
journal, January 2018


A review of cutting mechanics and modeling techniques for biological materials
journal, July 2017


Finite Element Modeling of Carbon Fiber Composite Orthogonal Cutting and Drilling
journal, January 2014


The Influence of Material Models on Finite Element Simulation of Machining
journal, November 2004

  • Shi, Jing; Liu, C. Richard
  • Journal of Manufacturing Science and Engineering, Vol. 126, Issue 4
  • DOI: 10.1115/1.1813473