A new thermomechanical model of cutting applied to turning operations. Part I. Theory

In this paper, an analytical approach is used to model the thermomechanical process of chip formation in a turning operation. In order to study the effects of the cutting edge geometry, it is important to analyse its global and local effects such as the chip flow direction, the cutting forces and the temperature distribution at the rake face. To take into account the real cutting edge geometry, the engaged part in cutting of the rounded nose is decomposed into a set of cutting edge elements. Thus each elementary chip produced by a straight cutting edge element, is obtained from an oblique cutting process. The fact that the local chip flow is imposed by the global chip movement is accounted for by considering appropriate interactions between adjacent chip elements. Consequently, a modified version of the oblique cutting model of Moufki et al. [Int. J. Mech. Sci. 42 (2000) 1205; Int. J. Mach. Tools Manufact. 44 (9) (2004) 971] is developed and applied to each cutting edge element in order to obtain the cutting forces and the temperature distributions along the rake face. The material characteristics such as strain rate sensitivity, strain hardening and thermal softening, the thermomechanical coupling and the inertia effects are taken into account in the modelling. The model can be used to predict the cutting forces, the global chip flow direction, the surface contact between chip and tool and the temperature distribution at the rake face which affects strongly the tool wear. Part II of this work consists in a parametric study where the effects of cutting conditions, cutting edge geometry, and friction at the tool–chip interface are investigated. The tendencies predicted by the model are also compared qualitatively with the experimental trends founded in the literature.     

The form error prediction in side wall machining considering tool deflection

In this research, an effective method for the form error prediction in side wall machining with a flat end mill is suggested. The form error is predicted directly from the tool deflection without surface generation by cutting edge locus with time simulation. The developed model can predict the surface form error accurately about 300 times faster than the previous method. Cutting forces and tool deflection are calculated considering tool geometry, tool setting error and machine tool stiffness. The characteristics and the difference of generated surface shape in up milling and down milling are discussed. The usefulness of the presented method is verified from a set of experiments under various cutting conditions generally used in die and mold manufacturing. This study contributes to real time surface shape estimation and cutting process planning for the improvement of form accuracy.     

A new thermomechanical model of cutting applied to turning operations. Part II. Parametric study

In Part I of this work, Molinari and Moufki [Int. J. Mach. Tools Manufact., this issue], an analytical model of three-dimensional cutting is developed for turning processes. To analyse the influences of cutting edge geometry on the chip formation process, global effects such as the chip flow direction and the cutting forces, and local effects such as the temperature distribution and the surface contact at the rake face have been investigated. In order to accede to local parameters, the engaged part in cutting of the rounded nose is decomposed into a set of cutting edge elements. Thus each elementary chip, produced by a straight cutting edge element, is obtained from an oblique cutting process defined by the corresponding undeformed chip section and the local cutting angles. The present approach takes into account the fact that for each cutting edge element the local chip flow is imposed by the global chip movement. The material characteristics such as strain rate sensitivity, strain hardening and thermal softening, the thermomechanical coupling and the inertia effects are considered in the modelling. A detailed parametric study is provided in this paper in order to analyse the effects of cutting speed, depth of cut, feed, nose radius and cutting angles on cutting forces, global chip flow direction and temperature distribution at the rake face. The influence of friction at the tool–chip interface is also discussed.     

Micro-end-milling of single-crystal silicon

Ductile-regime machining of silicon using micro-end-mill is almost impossible because of the brittle properties of silicon, crystal orientation effects, edge radius of the cutter and the hardness of tool materials. Micro-end-milling can potentially be used to create desired three dimensional (3D) free form surface features using the ductile machining technology for single-crystal silicon. There is still a lack of fundamental understanding of micro-end-milling of single-crystal silicon using diamond-coated tool, specifically basic understanding of material removal mechanism, cutting forces and machined surface integrity in micro-scale machining of silicon. In this paper, further research to understand the chip formation mechanism was conducted. An analysis was performed to discover how the chips are removed during the milling process. Brittle and ductile cutting regimes corresponding to machined surfaces and chips are discussed. Experiments have shown that single-crystal silicon can be ductile machined using micro-end-milling process. Forces generated when micro-end-milling single-crystal silicon are used to determine the performance of the milling process. Experimental results show that the dependence of the cutting force on the uncut chip thickness can be well described by a polynomial function order n. As cutting regime becomes more brittle, the cutting force has more complex function.     

深浅水中KVLCC船体横荡运动水动力数值计算

通过求解非定常RANS方程,选取SST k-ω湍流模型,采用全六面体网格进行离散,在忽略自由面兴波影响的情况下,对KVLCC1裸船体在深水和浅水中的PMM试验纯横荡运动粘性流场进行了数值模拟,计算了作用在船体上的水动力和力矩;通过将计算结果与现有的试验数据对比,验证了该文方法的有效性.在此基础上,根据水动力和力矩计算结果,计算得到了船舶横荡运动线性水动力导数.     

NUMERICAL SIMULATION OF FLOW OVER TWO CIRCULAR CYLINDERS IN TANDEM ARRANGEMENT

In this article,the 2-D unsteady viscous flow around two circular cylinders in a tandem arrangement is numerically simulated in order to study the characteristics of the flow in both laminar and turbulent regimes.The method applied alternatively is based on the finite volume method on a Cartesian-staggered grid.The great source term technique is employed to identify the cylinders placed in the flow field.To apply the boundary conditions,the ghost-cell technique is used.The implemented computational method is firstly validated through simulation of laminar and turbulent flows around a fixed circular cylinder.Finally,the flow around two circular cylinders in a tandem arrangement is simulated and analyzed.The flow visualization parameters,the Strouhal numbers,and drag and lift coefficients are comprehensively presented and compared for different cases in order to reveal the effect of the Reynolds number and gap spacing on the behavior of the flow.The obtained results have shown two completely distinct flow characteristics in laminar and turbulent regimes.     

一种三维刚架—桁架静力分析有限元程序

介绍了三维刚架计算原理以及作者所编制的一种应用于ＰＣ微机的有限元程序．本程序用＂ＦＯＲＴＲＡＮ＂语言编写,采用半动态一维存储．引入了单元整体形函数矩阵,简化了单元非结点载荷与结点载荷的转换过程．可用于计算三维及二维刚架或桁架在多种载荷条件下的位移及杆端内力并可绘出结构的有限元模型、支承、受载及变形状况．通过一系列算例验证了程序的正确性．     

聚焦部分相干平顶涡旋光束对瑞利粒子的捕获

基于广义惠更斯-菲涅尔原理和瑞利散射理论,推导了聚焦部分相干平顶涡旋(partially coherent flat-topped vortex, PCFTV)光束作用在瑞利微粒上辐射力的表达式,主要研究聚焦PCFTV光束对不同折射率的两种粒子的捕获情况。研究结果表明,聚焦PCFTV光束可以在焦点处捕获高折射率和低折射率的粒子。随着光束阶数的增大以及相关长度的减小,光束对微粒的捕获能力增强。所得结果对PCFTV光束应用于光学操控具有一定的意义。     

Influence of cryogenic coolant on turning performance characteristics: A comparison with wet machining

Machining of 17-4 Precipitation Hardenable Stainless Steel (PH SS) is one of the difficult tasks because of its high cutting temperatures. Conventional cutting fluids are used to overcome the high cutting temperatures, but these are not acceptable from the health and environmental sustainable points of view. Cryogenic cooling is one of the potential techniques to overcome such problems. In the current work, comparison is made of cryogenic turning results, such as tool flank wear, cutting forces (feed force, main cutting force), cutting temperature, chip morphology and surface integrity characteristics with wet machining during machining of heat-treated 17-4 PH SS. The result showed that in cryogenic machining, a maximum of 53%, 78%, 35% and 16% reductions was observed in tool flank wear, cutting temperature, surface roughness and cutting force, respectively, when compared with wet machining. It was also evident from the experimental results that cryogenic machining significantly improved the machining performance and product quality even at high feed rates.     

Cutting force and hole quality analysis in micro-drilling of CFRP

Micro-drilling in carbon fiber reinforced plastic (CFRP) composite material is challenging because this material machining is difficult due to anisotropic, abrasive and non-homogeneous properties and also downscaling of cutting process parameters affect the cutting forces and micro-drilled hole quality extensively. In this work, experimental results based statistical analysis is applied to investigate feed and cutting speed effect on cutting force components and hole quality. Analysis of variance based regression equation is used to predict cutting forces and hole quality and their trend are described by response surface methodology. Results show that roundness error and delamination factor have similar trends to those of radial forces and thrust force, respectively. Non-linear trends of cutting forces and hole quality errors are observed during downscaling of the micro-drill feed value. Optimization results show that cutting forces and hole quality errors are minimum at a feed value which is almost equal to the tool edge radius rather than at the lowest feed value. Therefore, the presented results clearly show the influences of size effects on cutting forces and hole quality parameters in micro-drilling of CFRP composite material.