On nonlinear cutting response and tool chatter in turning operation

Tool chatter in turning process is addressed with a new perspective. Turning dynamics is investigated using a 3D model that allows for simultaneous workpiece-tool deflections in response to the exertion of nonlinear regenerative force. The workpiece is modeled as a system of three rotors, namely, unmachined, being machined and machined, connected by a flexible shaft. Such a configuration enables the workpiece motion relative to the tool and tool motion relative to the machining surface to be three-dimensionally established as functions of spindle speed, instantaneous depth-of-cut, material removal rate and whirling. The equations of motion for the model are coupled through the nonlinear cutting force. The model is explored along with its 1D counterpart, which considers only tool motions and disregards workpiece vibrations. Different stages of stability for the workpiece and the tool subject to the same cutting conditions are studied. Numerical simulations reveal diverse, oftentimes inconsistent, tool behaviors described by the two models. Most notably, observations made with regard to the inconsistency in describing machining stability limits raise the concern for using 1D models to obtain stability charts.     

Modelling of metal forging using SPH

In solid metal forming processes, such as forging, large distortions in the material present challenging problems for numerical simulation using grid based methods. Computations invariably fail after some level of mesh distortion is reached unless suitable re-meshing is implemented to cope with the mesh distortion arising from the material deformation. The issue of mesh distortion and the subsequent re-meshing are topics of much research for grid based methods. These problems can be overcome by using a mesh-less numerical framework. In this paper, the application of a mesh-less method called Smoothed Particle Hydrodynamics (SPH) for modelling three-dimensional complex forging processes is demonstrated. It is shown that SPH is a useful simulation method for obtaining insights into the material deformation and flow pattern during forging of realistic industrial components. The effect of process parameters and material properties on the quality of the forged component is evaluated via SPH simulations. This includes the determination of forging force required for adequate die filling which is an important criterion for die designs. Material hardening, controlled by the degree of heat treatment, is found to have a profound effect on the material deformation pattern and the final product. Forging defects such as incomplete die filling, asymmetry in forged components, flashing and lap formation are shown to be predicted by SPH. SPH can thus potentially be used both for assessment of the quality of forged products and evaluation of prototype forging system designs.     

A Lagrangian-based SPH-DEM model for fluid–solid interaction with free surface flow in two dimensions

A Lagrangian-based SPH-DEM coupling model is proposed to study fluid–solid interaction (FSI) problems with free-surface flow. In this model, SPH uses an incompressible divergence-free scheme for simulating complex flow problems. Based on the Mohr–Coulomb criterion with tension cut, the DEM describes the characteristics of solid deformation and failure by means of contact models between particles. The coupling mechanism between SPH and DEM is realised by the decoupling of the force field during the process of fluid–solid interaction. That is, the motions of fluid and solid particles are reflected by the Navier–Stokes equations and interactions among solid particles are determined by Newton's second law in the DEM. To demonstrate the applicability of the SPH-DEM model, three case studies are used to verify the different fluid interaction situations with rigid bodies, deformable objects, and granular assemblies, respectively. The results of the proposed model shows good agreement with experimental data and indicates that it is capable of capturing the features of solid movement, deformation and failure under complex flow conditions with convincing accuracy and high efficiency.     

Configurational Forces in Crystal Plasticity

The surface morphology of micro machined surfaces depends on the heterogeneous microstructure. A crystal plasticity model is used to describe the plastic deformation in cp-titanium with its hcp crystal structure. Therefore the basal and prismatic slip systems are taken into account. Furthermore, self and latent hardening are considered. The rate dependency is motivated by a visco plastic evolution law. The cutting process of cp-titanium is modeled within the concept of configurational forces for a standard dissipative media. This framework is implemented into the finite element method. An example illustrates the effects of the microstructure on plastic deformation and configurational forces. (© 2013 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

An Expert System Framework for Economic Evaluation of Machining Operation Planning

Recognising the importance of combining manufacturing and management systems for machining operation planning, this paper presents a new methodology for the evaluation of economic aspects in an operation plan. To ensure that the quality of machined parts satisfies the required specifications, the manufacturing system acts as an alternative generator that provides meaningful and practical plans. Through cost analysis, the variable, fixed, and total costs associated with the machining operation are quantitatively determined. The management system, which functions as an evaluation mechanism, then selects the optimal plan based on the defined goal. The proposed methodology has been applied in the framework design of an expert system. The program establishes a sequence of machining operation planning and searches for the optimal plan. This optimal plan integrates considerations from both managers and production engineers, and balances their needs for efficient machining of a quality product.     

Modeling of van der Waals force with smoothed particle hydrodynamics: Application to the rupture of thin liquid films

The rupture of thin liquid films driven by the van der Waals force is of significance in many engineering processes, and most previous studies have relied on the lubrication approximation. In this paper, we develop a smoothed particle hydrodynamics (SPH) representation for the van der Waals force and simulate the rupture of thin liquid films without resort to lubrication theory. The van der Waals force in SPH is only imposed on one layer, i.e., the outermost layer of fluid particles, where a weighting function is deployed to evaluate the contributions of particles on or near the interface. However, to obtain an accurate hydrostatic pressure in reaction to the van der Waals force, a smaller smoothing length is used for the calculation of the weighting function than that used for SPH discretizations of the bulk fluid. The same surface particles are also used to model the surface tension. To deal with the rupture of a thin liquid film with a very small aspect ratio ε (ε = thickness/length), a coordinate transformation is introduced to shrink the length of the liquid film to achieve accurate numerical resolution with a manageable number of particles. As verifications of our physical model and numerical algorithm, we simulate the hydrostatic pressure in a stationary film and the relaxation of an initially square droplet and compare the SPH results with the analytical solutions. The method is then applied to simulate the rupture of thin liquid films with moderate and small aspect ratios (ε = 0.5 and 0.005). The convergence of the method is verified by refining particle spacing to four different levels. The effect of the capillary number on the rupture process is analyzed.     

Modeling and numerical study of thermal-compression bonding in the packaging process using NCA

Packaging technology used in liquid crystal displays (LCDs) faces the critical issues such as high density interconnects, thinner packaging size, and environmental safety. In order to reduce the packaging size, driver integrated circuit (IC) chips are directly attached to LCD panels using flip chip technology with adhesives, which is called chip on glass (COG) packaging processes. To investigate the effects of the bonding force and bonding temperature on the flip chip thermal-compression packaging, this study established a compression model to analyze the flip chip packaging processes with non-conductive adhesives (NCAs). The plastic deformation of bumps and the NCA flow dynamics between chip and substrate were taken into account in this model. The gap height, bump deformation, bump contact area, and residual stresses after bonding can be estimated with this model.According to the simulation in this work, the best tactic for the flip chip packaging process using NCA is bonded at a lower temperature. This reduces the maximum warpage and only slightly decreases the average compressive residual stress in the bottom of bumps. A larger bonding force results in a larger bump contact area with the substrate, but has a lower compressive residual stress at the contact areas. The bonding force during the flip chip thermal bonding process will affect the contact resistance and reliability of packaging at the same time.     

Hopf bifurcation for delay differential equation with application to machine tool chatter

In the machining process, unstable self-excited vibrations known as regenerative chatter can occur, causing excessive tool wear or failure, and a poor surface finish on the machined workpiece, hence the relevant measures must be taken to predict and avoid this phenomenon of instability. In this paper, we propose a weakly nonlinear model with square and cubic terms in both structural stiffness and regenerative terms, to represent self-excited vibrations in machining. It is proved that Hopf bifurcation exists when bifurcation parameter equals a critical value, a formula for determining the direction of the Hopf bifurcation and the stability of bifurcating periodic solutions are given by using the normal form method and center manifold theorem. Numerical simulations show excellent agreement with the theoretical results.     

Modeling unsteady flow characteristics using smoothed particle hydrodynamics

Smoothed particle hydrodynamics (SPH) method has been extensively used to simulate unsteady free surface flows. The works dedicated to simulation of unsteady internal flows have been generally performed to study the transient start up of steady flows under constant driving forces and for low Reynolds number regimes. However, most of the fluid flow phenomena are unsteady by nature and at moderate to high Reynolds numbers. In this study, first a benchmark case (transient Poiseuille flow) is simulated to evaluate the ability of SPH to simulate internal transient flows at low and moderate Reynolds numbers (Re = 0.05, 500 and 1500). For this benchmark case, the performance of the two most commonly used formulations for viscous term modeling is investigated, as well as the effect of using the XSPH variant. Some points regarding using the symmetric form for pressure gradient modeling are also briefly discussed. Then, the application of SPH is extended to oscillating flows imposed by oscillating body force (Womersley type flow) and oscillating moving boundary (Stokes’ second problem) at different frequencies and amplitudes. There is a very good agreement between SPH results and exact solution even if there is a large phase lag between the oscillating pressure difference and moving boundary and the movement of the SPH particles generated. Finally, a modified formulation for wall shear stress calculations is suggested and verified against exact solutions. In all presented cases, the spatial convergence analysis is performed.     

A general mathematical model for two-parameter generating machining of involute cylindrical gears

Instead of the common analytical model for involute gears machining, a general mathematical model for two-parameter generating machining is developed in this study with adopting discrete enveloping to increase its robustness and generality for machined profile calculation and instant contact analysis. The geometric parameters and motion relationships are integrated according to the cross-axis gear meshing at first, and the enveloping theory for two-parameter generating process is analyzed briefly with involving middle gear rack. By transforming the multiple cutting edges relative to the gear blank according to the generating motions, a numerical algorithm is proposed to distinguish the external enveloping profile on the shaft section, then the derivation of instant contact points via the implied time sequences of profile points is introduced. Finally, the coordinate transformations for the spatial trajectory of instant contact points identifying and the engaged cutting edge segments distinguishing are investigated. At last, a non- involute profile skiving is performed to verify the generality and the robustness of proposed method, and several typically generating machining operations for cylindrical involute gear are simulated numerically to proof the accuracy of the proposed model by finding the deviations from the standard involute curves and the geometries of the instant contact points.     

Vibration surveillance during milling of flexible details with a use of the optimal control

The paper concerns vibration surveillance during ball end milling of curved flexible details. Here is explained dynamic analysis of non-stationary vibrating system, from which are separated subsystems: modal, structural and connective. An assessment of coincidence of the calculation model results with those from investigation on milling machine is performed. Ball end milling of flexible details is observed very frequently in case of modern machining centres. It is obvious that tool-workpiece relative vibration plays principal role during cutting process. The most important task is to create a FE-model of machined flexible detail and obtain its good correlation with the results of experimental modal analysis. (© 2009 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Chaotic vibrations in a regenerative cutting process

We have analysed vibrations generated in an orthogonal cutting process. Using a simple one degree of freedom model of the regenerative cutting, we have observed the complex behaviour of the system. In presence of a shaped cutting surface, the nonlinear interaction between the tool and a workpiece leads the to chatter vibrations of periodic, quasi-periodic or chaotic type depending on system parameters. To describe the profile of the surface machined by the first pass we used a harmonic function. We analysed the impact phenomenon between the tool and a workpiece after their contact loss.     

Surface Deformation due to Shear and Ploughing in a Halfspace

Sheet and bulk metal forming are widely used manufacturing methods. The interaction between worktool and workpiece in such a process causes friction which has a remarkable impact on the expended energy of the process. Therefore the influence of friction is important. Friction can be split into shearing and ploughing [1]. Ploughing is the plastic deformation of a soft surface by a hard contact partner. Shear forces are only transferred in the real contact area where material contact occurs. The investigation of the contribution of both ploughing and shearing to the total friction resistance is done with the use of an elasto-plastic halfspace model. The multiscale character of surfaces demands a fine discretization, which results in numerical effort. While a finite element method takes into account both surface and bulk of the contact partners, the halfspace model only regards the contact surfaces and thereby consumes less computing capacity. In order to identify the friction resistance, two rough surfaces get into contact. After full application of the normal load, the surfaces are moved relatively to each other. New asperities of the contact surfaces get into contact and are plastically deformed. These deformations are used to estimate the ploughing effect in dependency on the relative displacement. (© 2014 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

三维PTT黏弹性液滴撞击固壁面问题的改进SPH模拟

基于光滑粒子动力学(smoothed particle hydrodynamics, SPH)方法,对三维Phan-Thien Tanner(PTT)黏弹性液滴撞击固壁面问题进行了数值模拟.为了有效地防止粒子穿透固壁,且缩减三维数值模拟所消耗的计算时间,提出了一种适合三维数值模拟的改进固壁边界处理方法.为了消除张力不稳定性问题,采用一种简化的人工应力技术.应用改进SPH方法对三维PTT黏弹性液滴撞击固壁面问题进行了数值模拟,精细地捕捉了液滴在不同时刻的自由面,讨论了PTT黏弹性液滴不同于Newton(牛顿)液滴的流动特征,分析了PTT拉伸参数对液滴宽度、高度和弹性收缩比等的影响.模拟结果表明,改进SPH方法能够有效而准确地描述三维PTT黏弹性液滴撞击固壁面问题的复杂流变特性和自由面变化特征.     

Three dimensional modelling of lava flow using Smoothed Particle Hydrodynamics

The paper describes the use of the grid-free Smoothed Particle Hydrodynamics (SPH) method to investigate lava flow from volcanic eruptions using real three dimensional topography in the form of Digital Terrain Models (DTM). Heat transfer resulting from conduction and radiation and solidification of the lava modelled via a variable viscosity are coupled to the fluid flow solution. Simulations show that the run-out distance and the nature of the lava flow are affected significantly by the lava viscosity and that this is dependent on the scale of the volcanic eruption, with solidification effects strongest on the smallest scale. SPH appears to be a highly effective technique for predicting lava flow with very good representations of the fluid free surface, close interaction with the complex topography, easy inclusion of the thermal and solidification effects leading to very plausible flow predictions. The pile-up of the lava at the front as it solidifies and the subsequent deceleration of the flow are easily modelled by SPH.     

Multiscale modelling and simulation of micro machining of titanium

The microscale morphology of micro machined component surfaces is directly connected to the heterogeneous microstructure. The deformation depends on the crystal structure, in case of the considered cp-titanium, the hcp crystal structure. In a first approach the crystal plastic deformation is modeled with isotropic hardening. A visco-plastic evolution law accounts for the rate dependency. The concept of configurational forces is used with the framework of crystal plasticity to model the cutting process of cp-titanium. The setting is implemented into the finite element method. The examples show the effect of the material heterogeneity on the deforamtion behavior and on the related configurational forces. (© 2012 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Analytical modeling of chatter stability using multi-dimensional approach

Machining is one of the most common manufacturing processes in industry due to its high flexibility and ability to produce parts which excellent quality. Chatter, a type of self excited vibrations arising in metal cutting operations, is a major limitation in machining resulting in poor quality and reduced productivity. Under certain conditions, the cutting process may become unstable yielding oscillations with high amplitudes and cutting forces. Stability analysis of the dynamic cutting process can be used to determine chatter-free machining conditions with high material removal rate. Usually, one dimensional models are used for stability analysis of machining. However, based on the geometry of the actual machining process, multi-directions would have to be used for accurate modeling of the process dynamics and the stability. In this presentation, multi directional models for turning and milling processes are presented. The effects of multi directional process mechanics on the stability are demonstrated by applications. (© 2008 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Spindle Speed Variation for the Suppression of Regenerative Chatter

Summary. A phenomenon commonly encountered during machining operations is chatter. It manifests itself as a vibration between workpiece and cutting tool, leading to poor dimensional accuracy and surface finish of the workpiece and to premature failure of the cutting tool. A chatter suppression method that has received attention in recent years is the spindle speed variation method, whereby greater widths of cut are achieved by modulating the spindle speed continuously. By adapting existing mathematical techniques, a perturbative method is developed in this paper to obtain finite-dimensional equations in order to systematically study the mechanism of spindle speed variation for chatter suppression. The results indicate both modest increase of stability and complex nonlinear dynamics close to the new stability boundary. The method developed in this paper can readily be applied to any other system with time-delay characteristics.     

Application of a rule self-regulating fuzzy controller for robotic deburring on unknown contours

Most metal parts made by machining operations contain burrs, which can be removed by robotic manipulators. Modeling a deburring robot on unknown contours is a relatively difficult task. In this study, we present a novel compliant motion controller that uses a modified on-line rule self-regulating fuzzy control (RSFC) and depends on no mathematical models. In the proposed controller, a Cartesian robot on which a grinding tool is mounted rigidly performs edge following (precision deburring) and chamfering on unknown contours. The manipulator is controlled along the tangential direction of a constrained surface and its cutting force is maintained at a desired level. Experimental results demonstrate the effectiveness of this control strategy in terms of automatically deburring the edges of parts with an unknown geometrical configuration.     

Prediction of diameter errors in bar turning: a computationally effective model

Machining accuracy can be considerably affected by the deflections of the machine–workpiece–tool system as well as the thermal expansion of material during machining. An improved model for predicting dimensional errors in turning process is presented. This model uses a geometric analysis in the machine frame, in which the elastic deflections of the machine–workpiece–tool system due to the cutting force are studied. In this paper, our workpiece deflection model [A.-V. Phan, G. Cloutier, J.R.R. Mayer, International Journal of Production Research 37 (1999) 4039–4051; G. Cloutier, J.R.R. Mayer, A.-V. Phan, Computer Modeling and Simulation in Engineering 4 (1999) 133–137] earlier developed is employed. As described in Phan et al. (1999), this deflection model is general, accurate and computationally effective thanks to its closed-form solutions derived from the finite element technique. Also, due to the coupling between the cutting force and actual depth of cut, iterative computations are performed to obtain the coupling value of this force which provides further accuracy to the prediction. Finally, via numerical examples, the predicted diameter error on a workpiece, the ratio between the coupled cutting force and its nominal value along the part axis as well as the influence of the cutting force components on the error prediction are computed using the proposed model. The results provide additional insight into the error formation in the turning process.