O.B. Adetoro

STABILITY LOBES PREDICTION FOR CORNER RADIUS END MILL USING NONLINEAR CUTTING FORCE COEFFICIENTS

There are a vast number of different types of end mill tools used in the manufacturing industry, each type with a unique shape. These tool shapes have a direct influence on the cutting force it generates during machining. This article presents a more accurate approach to predicting the stability margin in machining by considering the cutting force coefficients and axial immersion angle as variables along the axial depth of cut. A numerical approach to obtaining a converged solution to the stability model is presented. The results obtained are validated using experimental results and a very good agreement is seen.

Benchmark 2 – Springback of a Jaguar Land Rover Aluminium

The aim of this benchmark is the numerical prediction of the springback of an aluminium panel used in the production of a Jaguar car. The numerical simulation of springback has been very important for the reduction of die try outs through the design of the tools with die compensation, thereby allowing for the production of dimensionally accurate complex parts at a reduced cost. The forming stage of this benchmark includes one single forming operation followed by a trimming operation. Cross-sectional profiles should be reported at specific (provided) sections in the part before and after springback. Problem description, tool geometries, material properties, and the required simulation reports are summarized in this benchmark briefing.

On contact modelling in isogeometric analysis

Abstract IsoGeometric Analysis (IGA) has proved to be a reliable numerical tool for the simulation of structural behaviour and fluid mechanics. The main reasons for this popularity are essentially due to: (i) the possibility of using higher order polynomials for the basis functions; (ii) the high convergence rates possible to achieve; (iii) the possibility to operate directly on CAD geometry without the need to resort to a mesh of elements. The major drawback of IGA is the non-interpolatory characteristic of the basis functions, which adds a difficulty in handling essential boundary conditions and makes it particularly challenging for contact analysis. In this work, the IGA is expanded to include frictionless contact procedures for sheet metal forming analyses. Non-Uniform Rational B-Splines (NURBS) are going to be used for the modelling of rigid tools as well as for the modelling of the deformable blank sheet. The contact methods developed are based on a two-step contact search scheme, where during the first step a global search algorithm is used for the allocation of contact knots into potential contact faces and a second (local) contact search scheme where point inversion techniques are used for the calculation of the contact penetration gap. For completeness, elastoplastic procedures are also included for a proper description of the entire IGA of sheet metal forming processes.

Non-Local Damage Modelling of Sheet Metal Forming Processes with ALE Formulation

The modelling of material degradation due to nucleation, growth and coalescence of micro-voids is vital in sheet metal forming process due to the large deformation typically experienced by the part. Nonlocal damage modelling or nonlocal continuum is gaining a lot of interest because it is an effective approach to modelling the strain-softening, whilst avoiding the spurious localization that gives rise to strong mesh sensitivity in numerical computations. However to accurately resolve the evolving narrow bands of highly localised strain, it is necessary to use sufficient computational grids. In this paper an ALE formulation is used for modelling the localization pattern. An approach for relocating the node points is presented and explored.

Trimming Simulation of Forming Metal Sheets Isogeometric Models by Using NURBS Surfaces

Some metal sheets forming processes need trimming in a final stage for achieving the net-shape specification and for removing micro-cracks and irregularities. In numerical simulation, since the exact final edge location is a priori unknown in the original metal blanket, the trimming needs to be done once the forming is finished. During the forming internal stresses are generated inside the sheet. When trimming those stresses configuration is changed to achieve equilibrium as a consequence of the material removal. In this paper a novel method for simulating the trimming is presented. The part to trim is modelled using isogeometric analysis (IGA). The new surface generated is modelled with non-uniform rational B-splines (NURBS). Due to the IGA characteristics a total geometrical accuracy and an efficient residual stresses recalculation are accomplished.

Contact Modelling in Isogeometric Analysis: Application to Sheet Metal Forming Processes

Isogeometric Analysis (IGA) has been growing in popularity in the past few years essentially due to the extra flexibility it introduces with the use of higher degrees in the basis functions leading to higher convergence rates. IGA also offers the capability of easily reproducing discontinuous displacement and/or strain fields by just manipulating the multiplicity of the knot parametric coordinates. Another advantage of IGA is that it uses the Non-Uniform Rational B-Splines (NURBS) basis functions, that are very common in CAD solid modelling, and consequently it makes easier the transition from CAD models to numerical analysis. In this work it is explored the contact analysis in IGA for both implicit and explicit time integration schemes. Special focus will be given on contact search and contact detection techniques under NURBS patches for both the rigid tools and the deformed sheet blank.

On the Numerical Prediction of Stability in Thin Wall Machining

In this chapter, the numerical prediction of stability margin in thin wall machining is introduced. The Nyquist criterion is applied to the stability model presented by Adetoro, while a newly discovered damping prediction approach is presented, which when applied to the FEM and Fourier approach presented by Adetoro, would allow the prediction of stability margins without the need for experimentally extracted damping parameters.