Paul Mativenga

Numerical simulation of laser machining of carbon-fibre-reinforced composites:

Abstract The growing use of carbon-fibre-reinforced polymer (CFRP) composites as high-performance lightweight materials in aerospace and automotive industries demands efficient and low-cost machining technologies. The use of laser machining for cutting and drilling composites is attractive owing to its high speed, flexibility, and ease of automation. However, the anisotropic material properties of composites, and issues related to the heat-affected zone (HAZ), charring, and potential delamination during laser processing, are major obstacles in its industrial applications. In order to improve the quality and dimensional accuracy of CFRP laser machining, it is important to understand the mechanism of the transient thermal behaviour and its effect on material removal. Based on the ‘element death’ technique of the finite element (FE) method, a three-dimensional model for simulating the transient temperature field and subsequent material removal has been developed, for the first time, on a heterogeneous fibre—matrix mesh. In addition to the transient temperature field, the model also predicts the dimensions of the HAZ during the laser machining process. Experimental results obtained with same process variables using a 355 nm DPSS Nd:YVO4 laser were used to validate the model. Based on the investigation, the mechanism of material removal in laser composite machining is proposed. The results suggest that the employed FE approach can be used to simulate pulsed laser cutting of fibre-reinforced polymer composites.

Characterization of machining of AISI 1045 steel over a wide range of cutting speeds. Part 1: Investigation of contact phenomena

Abstract Friction conditions at the tool-chip interface are one of the most important inputs for modelling and simulation of the machining process. However, the nature of the tool-chip contact is often assumed in developing finite element models, thereby seriously affecting their reliability. In this paper, results of an investigation into the tool-chip contact interface using uncoated tungsten-based cemented carbide tools in dry high-speed turning of AISI 1045 steel are presented. The tests were conducted at cutting speeds ranging between 198 and 879m/min with a feed rate of 0.1mm/rev and a constant depth of cut of 2.5 mm. The effects of cutting speed on tool rake face contact length, contact area, friction, element mapping, and surface roughness are studied and discussed. It is shown that the quantitative methods, used here to characterize the tool-chip contact region, can provide valuable data for accurate and reliable modelling of the metal machining process over a wide range of cutting speeds.

An investigation of the tool¿chip contact length and wear in high-speed turning of EN19 steel

Abstract In this paper, existing models for the tool-chip contact length are reviewed with regards to high-speed machining theory. Results of an investigation into the tool-chip contact length and tool wear of uncoated tungsten-based cemented carbide tools for dry high-speed turning of EN19 alloy steel are presented. The tests were conducted at cutting speeds ranging between 200 and 1200m/min with feed rates of 0.14 and 0.2 mm/rev and a constant depth of cut of 0.1 mm. From measurements, the effect of cutting speed on contact length and tool life has been determined and several important relationships established. It was found that the contact length changes according to the contact phenomena in the tool-chip interface zone, which is predominantly affected by the cutting speed. Moreover, the influence of the cutting speed on the contact length changes significantly from conventional to high-speed cutting environments. The study concludes that existing models are quantitatively inadequate for predicting tool-chip contact lengths in high speed turning.

Characterization of machining of AISI 1045 steel over a wide range of cutting speeds. Part 2: Evaluation of flow stress models and interface friction distribution schemes

Abstract To ensure that the simulation of the orthogonal metal-cutting process yields accurate results, the material and frictional behaviours during simulation have to be defined accurately. Flow stress models are used extensively in the simulations of deformation processes occurring at high strains, strain rates, and temperatures. In this work, the Johnson-Cook, Maekawa et al., Oxley, El-Magd et al., and Zerilli-Armstrong flow stress models are evaluated. AISI 1045 steel is used as the workpiece material because it is well characterized. First, the predictive capability of these flow stress models is compared with the published experimental data at high strain rates and the modelling errors are quantified. Different friction conditions along the tool rake face are also discussed. Then the friction conditions based on results of scanning electron microscopy-energy-dispersive X-ray analysis from Part 1 are implemented together with other friction models. The material flow stress models and friction conditions are assessed using an updated Lagrangian finite element code simulating continuous chip formation over a range of cutting speeds. The assessment of these models is carried out for their accuracy in predicting the cutting force and shear angle with those obtained experimentally in order to draw conclusions regarding their comparative performance.

Micromachining of coarse-grained multi-phase material

Abstract The high demand of miniaturized components, coupled with geometric and material range limitations of traditional lithographic techniques has generated a strong interest in micromechanical machining. In micromachining the so-called size effect is a dominant factor. This is attributed to the fact that the unit or physical size of the material to be removed can be of the same order of magnitude as the tool edge radius or grain size. This paper explores the micro-machinability of multi-phase ferrite—pearlite steel that has a relatively large average grain size (10 μm). The investigation and cutting tests examined the effect of undeformed chip thickness, tool edge radius, and workpiece grain size on the specific cutting force, burr size, surface finish, and tool wear. The work clearly shows that micro tool edge radius and workpiece material grain size are valuable inputs in determining micromilling conditions that ensure the best surface finish and reduced burr size. Cutting conditions recommendations are also put forwards for roughing and finishing passes in micromilling of AISI 1045 tool steel.

Finite element modelling of substrate thermal distortion in direct laser additive manufacture of an aero-engine component

The shape complexity of aerospace components is continuously increasing, which encourages researchers to further refine their manufacturing processes. Among such processes, blown powder direct laser deposition process is becoming an economical and energy efficient alternative to the conventional machining process. However, depending on their magnitudes, the distortion and residual stress generated during direct laser deposition process can affect the performance and geometric tolerances of manufactured components. This article reports an investigation carried out using the finite element analysis method to predict the distortion generated in an aero-engine component produced by the direct laser deposition process. The computation of the temperature induced during the direct laser deposition process and the corresponding distortion on the component was accomplished through a three-dimensional thermo-structural finite element analysis model. The model was validated against measured distortion values of the real component produced by direct laser deposition process using a Trumpf DMD505 CO2 laser. Various direct laser deposition fill patterns (orientation strategies/tool movement) were investigated in order to identify the best parameters that will result in minimum distortion.

Estimation of minimum chip thickness in micro-milling using acoustic emission:

In micro-machining, determination of the minimum chip thickness is of paramount importance, as features having dimensions below this threshold cannot be produced by the process. This study proposes a methodology to determine the value of minimum chip thickness by analysing acoustic emission (AE) signals generated in orthogonal machining experiments conducted in micro-milling. Cutting trials were performed on workpiece materials ranging from non-ferrous (copper and aluminium), ferrous (single- and multiphase steel) to difficult-to-cut (titanium and nickel) alloys. The characteristics of AErms signals and chip morphology were studied for conditions when the tool was rubbing the workpiece. This provided a foundation to contrast AE signals captured at higher feed rates. This study enabled the identification of threshold conditions for the occurrence of minimum chip thickness. The values of minimum chip thickness predicted by this new approach compare reasonably well with the published literature.

An evaluation of heat partition in the high-speed turning of AISI/SAE 4140 steel with uncoated and TiN-coated tools

Abstract In manufacturing by machining, thermal loads on cutting tools can have a major influence on tool wear and hence process cost, especially at higher cutting speeds. An investigation has been undertaken to determine heat partition into the cutting tool for high-speed machining of AISI/SAE 4140 high-strength alloy steel with uncoated and TiN-coated tools. The cutting tests have been performed at cutting speeds ranging between 100 and 880 m/min with a feed rate of 0.1 mm/rev and a constant depth of cut of 2.5 mm. Cutting temperatures are measured experimentally using an infrared thermal imaging camera. The sticking and sliding regions are investigated from an examination of the tool—chip contact region using a scanning electron microscope (SEM). In addition, non-uniform heat intensity is modelled according to the contact phenomena. In this work, evaluation of the fraction of heat flowing into the cutting tool is carried out by iteratively reducing the available heat flux until the finite element method (FEM) temperatures are simultaneously matched at multiple points with the experimentally measured temperatures. This paper elucidates on the differences in thermal shielding for uncoated and TiN-coated tools. It is found that heat partition into the cutting tool decreases from a fraction of 0.41 to 0.17 for conventional cutting speeds and increases from 0.19 to 0.24 for high-speed machining when using uncoated carbide cutting tools. On the other hand, with TiN-coated tools, heat partition varies from 0.35 down to 0.095 for the whole range of cutting speeds. These results clearly show that the use of TiN-coated tools generally reduces heat partition into the cutting tool, but does so more significantly in high-speed machining (HSM) as compared with conventional machining speeds. The driver behind this study on heat partition in machining with TiN coatings is the design of coatings with enhanced thermal shielding properties.

An experimental investigation of deep-hole microdrilling capability for a nickel-based superalloy

This paper presents the results of an experimental investigation into the feasibility of deep-hole microdrilling a nickel-based superalloy. This material is very challenging to machine and current drilling methods are based on non-conventional machining technologies; the traditional view is that microdrills are too fragile to be used for drilling this high-strength aerospace alloy. The work investigated mechanical microdrilling under various cutting conditions. Mechanical microdrilling may offer the chance of improved hole quality and surface integrity. Initially a review of literature was undertaken with a view to identify the best drill geometry for the production of micro holes in nickel-based alloys. Based on this review the best available commercial micro drills were selected. A special strategy was introduced for selecting the pilot drill in order to ensure gradual loading of the twist drill and reduce the chance of drill breakage. For the cutting tests, 0.5 mm diameter twist drills were used in drilling tests to a depth of 5 mm. The effect of processing parameters such as drill feed rate, spindle speed, and peck depth were evaluated, and the tool wear mechanism was also investigated. The cutting performance was characterized by the number of holes produced before drill breakage. The results show that deep-hole mechanical microdrilling of nickel-based superalloys is technically feasible and offers good hole definition and potentially competitive lead times.

Statistical analysis of process parameters in micromachining of Ti-6Al-4V alloy

The demand for miniaturized components is on the rise, especially from the biomedical and aerospace industry. As a result, there is a strong research potential towards the micro-manufacturing of biomedical and aerospace components. Titanium-based alloys are known for their biocompatibility and high strength-to-weight ratio, making them most suitable for such applications. In this research, flank wear progression, surface roughness and side burrs, the basic performance parameters of a typical micromachining operation, are presented and analysed through analysis of variance in order to determine the key process parameters. It was found that micromachining can be classified into two categories: micromachining with undeformed chip thickness below the tool edge radius and micromachining keeping the undeformed chip thickness above the tool edge radius. The results showed that when machining with undeformed chip thickness above edge radius, the feedrate remains the most significant parameter affecting tool wear (41% contribution ratio), surface roughness (83%) and burr width (80%). This result places this type of machining closer to macro-machining where feed contribution was found to be 69%, 92% and 75% as against micromachining below edge radius, where contributions stood at 17%, 53% and 52% on tool wear, surface roughness and burr width, respectively. The results underscored the importance of considering the tool edge radius in micromachining.