Numerical simulation of powder mixed electric discharge machining (PMEDM) using finite element method

In the present paper, an axisymmetric two-dimensional model for powder mixed electric discharge machining (PMEDM) has been developed using the finite element method (FEM). The model utilizes the several important aspects such as temperature-sensitive material properties, shape and size of heat source (Gaussian heat distribution), percentage distribution of heat among tool, workpiece and dielectric fluid, pulse on/off time, material ejection efficiency and phase change (enthalpy) etc. to predict the thermal behaviour and material removal mechanism in PMEDM process. The developed model first calculates the temperature distribution in the workpiece material using ANSYS (version 5.4) software and then material removal rate (MRR) is estimated from the temperature profiles. The effect of various process parameters on temperature distributions along the radius and depth of the workpiece has been reported. Finally, the model has been validated by comparing the theoretical MRR with the experimental one obtained from a newly designed experimental setup developed in the laboratory.     

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.     

Transient Finite Element Simulation of the Temperature Field during Cryogenic Turning of Metastable Austenitic Steel AISI 347

The process chain in manufacturing often consists of many steps. As part of current researches the possibility of combining two process steps, turning and hardening, is investigated to optimize the manufacturing time and to decrease the energy consumption of the process. For metastable austenitic steels, deformation induced hardening during turning can be used to achieve surface hardening [1] and thus to increase the wear resistance [2] as well as the fatigue strength [3], by applying high passive forces onto the workpiece. This enables an austenite-martensite phase transformation, for which it is necessary to maintain low process temperatures, typically below room temperature. Thus, cryogenic coolants are applied [4]. For a better understanding of the influence of cutting parameters on the process temperatures and thus martensite formation, knowledge of the exact temperature distribution in the workpiece and in the contact zone between workpiece and tool is essential. Since the experimental determination of the temperature field is hardly possible, an inverse determination of the process temperatures via transient finite element simulation is performed. The present finite element approach only takes thermal loads into account. The simulations are performed in the finite element program FEAP (Finite Element Analysis Program) with an Eulerian mesh, which requires special consideration of the rigid body rotation of the workpiece. In order to prevent unphysical oscillations in the solution, introduced by the convective time derivative, a streamline upwind / Petrov–Galerkin stabilization scheme is utilized. (© 2016 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Mathematical modelling of chip thickness in micro-end- milling: A Fourier modelling

This study developed a model of undeformed chip thickness in micro-end-milling for the use in estimating cutting constants based on measured cutting forces. The proposed estimation method is based upon the invertibility of the average milling force model. In this paper, chip thickness in micro-end-milling was estimated by summing the thicknesses of the conventional chip component and the additional chip component. Thickness was then expressed in terms of Fourier series. The analyses showed that the fast convergence of Fourier series gives the Fourier chip thickness model sufficient accuracy when using only five terms of the truncated Fourier series for common micro-end-milling processes. The Fourier coefficients can be expressed in terms of the ratio of feed per tooth to cutter radius for different numbers of cutter teeth. The accuracy and conciseness of the chip thickness model enables the modelling of average cutting force in a closed form, which can be applied to identify the cutting constants. Cutting force experiments verify that the model prediction agrees very well with the experimental results.     

A novel cutting force modelling method for cylindrical end mill

This paper proposes a new and simplified method for the calibration of cutting force coefficients and cutter runout parameters for cylindrical end milling using the instantaneous cutting forces measured instead of average ones. The calibration procedure is derived for a mechanistic cutting force model in which the cutting force coefficients are expressed as the power functions of instantaneous uncut chip thickness (IUCT). The derivations are firstly performed by establishing mathematical relationships between instantaneous cutting forces and IUCT. Then, nonlinear algorithms are proposed to solve the established nonlinear contradiction equations. The typical features of this new calibration method lie in twofold. On the one hand, all derivations are directly based on the tangential, radial and axial cutting force components transformed from the forces which are measured in the workpiece Cartesian coordinate system. This transformation makes the calibration procedure very simple and efficient. On the other hand, only a single cutting test is needed to be performed for calibrating the cutting force coefficients that are valid over a wide range of cutting conditions. The effectiveness of the proposed method in developing cutting force model is demonstrated experimentally with a series of verification cutting tests.     

Towards the simulation of grinding processes – a thermoplastic single grain approach

The current work aims at the modelling and simulation of metal grinding processes with focus on the thermal behaviour resulting from the interaction of tool and workpiece. Starting from a two-dimensional model of a single grain, representative numerical experiments are carried out based on the variation of grain geometry and its spatial position relative to the workpiece to predict the resulting load-displacement-behaviour. Here, a thermoelastic viscoplastic constitutive model is used to capture thermal softening of the material taken into account. Referring to previous research, an adaptive remeshing scheme, based on a combination of error estimation and refinement indication is used to overcome mesh dependence, allowing to resolve the complex deformation patterns and to predict a realistic thermomechanical state of the resulting workpiece surface. (© 2011 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Study of the parameters in electrical discharge machining through response surface methodology approach

Whereas the efficiency of traditional cutting processes is limited by the mechanical properties of the processed material and the complexity of the workpiece geometry, electrical discharge machining (EDM) being a thermal erosion process, is subject to no such constraints. The lack of correlations between the cutting rate, the surface finish and the physical material parameters of this process made it difficult to use. This paper highlights the development of a comprehensive mathematical model for correlating the interactive and higher order influences of various electrical discharge machining parameters through response surface methodology (RSM), utilizing relevant experimental data as obtained through experimentation. The adequacy of the above the proposed models have been tested through the analysis of variance (ANOVA). Optimal combination of these parameters was obtained for achieving controlled EDM of the workpieces.     

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.     

On the role of energy in chip formation

The implicit code ABAQUS/Standard is used to simulate the formation of continuous and segmented chips. Using the described model, the idealized process of friction‐less machining of an elastic ideally‐plastic material is studied. It is shown that Merchant's classical shear angle relation does not hold, as chip formation does not minimize the energy as assumed by Merchant. The model is also used to study segmented chip formation using a realistic material law for the Titanium alloy Ti6Al4V at high cutting speeds.     

Numerical analysis of quenching – Heat conduction in metallic materials

Metallic materials present a complex behavior during heat treatment processes. In a certain temperature range, change of temperature induces a phase transformation of metallic structure, which alters physical properties of the material. Indeed, measurements of specific heat and conductivity show strong temperature-dependence during processes such as quenching of steel. Several mathematical models, as solid mixtures and thermal–mechanical coupling, for problems of heat conduction in metallic materials, have been proposed. In this work, we take a simpler approach without thermal–mechanical coupling of deformation, by considering the nonlinear temperature-dependence of thermal parameters as the sole effect due to those complex behaviors. The above discussion of phase transformation of metallic materials serves only as a motivation for the strong temperature-dependence as material properties. In general, thermal properties of materials do depend on the temperature, and the present formulation of heat conduction problem may be served as a mathematical model when the temperature-dependence of material parameters becomes important. For this mathematical model we present the error estimate using the finite element method for the continuous-time case.     

Modeling of cutting force prediction in machining high-volume SiCp/Al composites

Variations in cutting forces significantly influence the tool wear and part quality in machining high-volume SiC-particle-reinforced aluminum matrix (SiCp/Al) composites. Properties of the reinforcement SiC particles, such as size and volume fraction, contribute to the change in the cutting forces. This paper presents a cutting force model based on the geometrical and mechanical nature of the tool and workpiece, considering the effect of the SiC reinforcement particles. The cutting force is predicted as three components (F_z, F_x, and F_y) and the resultant cutting force F_τs. The cutting force was considered to generate three deformed zones: (a) shear deformed zone, (b) friction deformed zone on the chip–tool interface, (c) plow deformed zone. The effect of SiC reinforcement particles on friction deformed zone is analyzed emphatically. The friction force from friction deformed zone was obtained by calculating the sliding friction force and rolling friction force. To verify the feasibility and validity of the predicted model of cutting force, cutting experiments were performed with different combinations of cutting speed, feed rate, depth of cut, and tool nose radius. The predicted cutting force values demonstrate good agreement with the measured experimental cutting force values in most cutting conditions. The average percentages of the prediction error were 1.93%, 6.20%, and 10.48% for the F_z, F_x, and F_y components, respectively, thus proving the validity and accuracy of the predicted model of cutting forces.     

On a thermomechanical milling model

This paper deals with a new mathematical model to characterize the interaction between machine and workpiece in a milling process. The model consists of a harmonic oscillator equation for the dynamics of the cutter and a linear thermoelastic workpiece model. The coupling through the cutting force adds delay terms and further nonlinear effects. After a short derivation of the governing equations it is shown that the complete system admits a unique weak solution. A numerical solution strategy is outlined and complemented by numerical simulations of stable and unstable cutting conditions.     

Nonlinear dynamics of a machining system with two interdependent delays

The dynamics of turning by a tool head with two rows, each containing several cutters, is considered. A mathematical model of a process with two interdependent delays with the possibility of cutting discontinuity is analyzed. The domains of dynamic instability are derived, and the influence of technological parameters on system response is presented. The numeric analysis show that there exists specific conditions for given regimes in which one row of cutters produces an intermittent chip form while the other row produces continuous chips. It is demonstrated that the contribution of parametric excitation by shape roughness of an imperfect (unmachined) cylindrical workpiece surface is not substantial due to the special filtering properties of cutters that are uniformly distributed circumferentially along the tool head.     

A desktop computer model of the arc,weld pool and workpiece in metal inert gas welding

A sophisticated computational model of metal inert gas arc welding of aluminium alloys is presented. The arc plasma, the wire electrode and the workpiece are included in the computational domain self-consistently. The flow in the arc plasma and in the weld pool are calculated in three dimensions using equations of computational fluid dynamics, modified to take into account plasma effects and coupled to electromagnetic equations. The formation of metal vapour from the wire electrode and workpiece is considered, as is the mixing of the wire electrode alloy with the workpiece alloy in the weld pool. A graphical user interface (GUI) has been developed, and the model runs on standard desktop or laptop computers.The computational model is described, and results are presented for lap-fillet weld geometry. The importance of including the arc in the computational domain is shown. The predictions of the model show good agreement with measurements of weld geometry and weld composition. The GUI is introduced, and the application of the model to predicting the thermal history of the workpiece, which is the input information that is required for predicting important weld properties such as residual stress and distortion and weld microstructure, is discussed. Initial predictions of residual stress and distortion of the workpiece are presented.     

Normalized Dynamic Characterization and Application of Multiple Heat Storage Materials Based on Standard Thermal Resistance北大核心CSCD

基于标准热阻和能量流法,推导出储热材料与换热流体的瞬态换热热阻,通过类比电路分析法,获得了储热-换热过程的瞬态热量流模型及动态响应时间常数。进一步引入节点温度,重新定义换热热阻,获得了储热与换热过程耦合的三阶电路瞬态热量流模型,求解得到了加热、储热和释热三类时间常数,可用于协同表征储热材料中储热与释热的快慢程度,从而实现了多类储热材料的归一化动态表征。通过数值模拟验证与应用对比分析,发现基于多时间常数的归一化动态模型用于表征储热材料的动态特性是可行的,可直接对不同换热、储热材料进行对比分析。案例分析发现与固体储热材料换热时,液态金属的动态换热能力优于熔融盐,而相比于水蒸气和CO₂,空气与陶瓷材料换热能更快达到稳态。     

A superstatistical model for anomalous heat conduction and diffusion

We propose a superstatistical model for anomalous heat conduction and diffusion, which is formulated by the thermal conductivity distribution, overall temperature and heat flux distributions. Our model obeys Fourier's law and the continuity equation at the individual level. The evolution of the thermal conductivity distribution is described by an advection-diffusion equation. We show that the superstatistical model predict anomalous behaviors including the time-dependent effective thermal conductivity and slow long-time asymptotics. The time-dependence of the effective thermal conductivity is determined by the mean square displacement (MSD), which coincides with existing investigations. The superstatistical structure can also be extended into other non-Fourier models including the Cattaneo and fractional-order heat conduction models.     

Application of a lumped model to solids with linearly temperature-dependent thermal conductivity

The application of a simple lumped model to unsteady cooling (or heating) processes in solids involving heat convection is limited by the value of the Biot number, Bi. For Bi < 0.1, assuming constant thermal properties, the lumped model approximates the exact solutions with only a small error. In this paper we study the lumped model for a 1-D rectangular solid, when thermal conductivity depends linearly on temperature, a type of dependence very common in metals and alloys at a wide range of working temperatures. From the study, new limits for the Biot are deduced as a function of a sole dimensionless parameter defined from the extreme values of thermal conductivity. The Biot limits depend on the thermal process (heating or cooling) and on the type of temperature dependence—positive or negative.     

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.     

异质材料有限长微通道电渗流热效应

采用数值方法,分析有限长PDMS/玻璃微通道电渗流热效应．数值求解双电层的Poisson-Boltzmann方程,液体流动的Navier-Stokes方程和流-固耦合的热输运方程,分析二维微通道电渗流的温度特性．考虑温度变化对流体特性（介电系数、粘度、热和电传导率）的反馈效应．数值结果表明,在通道进口附近有一段热发展长度,这里的流动速度、温度、压强和电场快速变化,然后趋向到一个稳定状态．在高电场和厚芯片的情况下,热发展长度可以占据相当一部分的微通道．电渗流稳定态温度随外加电场和芯片厚度的增加而升高．由于壁面材料的热特性差异,在稳定态时的PDMS壁面温度比玻璃壁面温度高．研究还发现在微通道的纵向和横向截面有温度变化．壁面温升降低双电层电荷密度．微通道纵向温度变化诱发流体压强梯度和改变微通道电场特性．微通道进流温度不改变热稳定态的温度和热发展长度．