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Conventional and micro scale finite element modeling for metal cutting process:A review

Chinese Journal of Aeronautics 2024年第2期37卷 199-232页

作者： Le WANG caixu yue Xianli LIU Ming LI Yongshi XU Steven Y.LIANG Key Laboratory of Advanced Manufacturing and Intelligent Technology Ministry of EducationHarbin University of Science and TechnologyHarbin 150080China George W.Woodruff School of Mechanical Engineering Georgia Institute of TechnologyAtlanta 30332USA

The metal cutting process is accompanied by complex stress field,strain field,temperature field.The comprehensive effects of process parameters on chip morphology,cutting force,tool wear and residual stress are complex and inter-connected.Finite element method(FEM)is considered as an effective method to predict process variables and reveal microscopic physical phenomena in the cutting process.Therefore,the finite element(FE)simulation is used to research the conventional and micro scale cutting process,and the differences in the establishment of process variable FE simulation models are distinguished,thereby improving the accuracy of FE simulation.The reliability and effectiveness of FE simulation model largely depend on the accuracy of the simulation method,constitutive model,friction model,damage model in describing mesh element,the dynamic mechanical behavior of materials,the tool-chip-workpiece contact process and the chip formation mechanism.In this paper,the FE models of conventional and micro process variables are comprehensively and up-to-date reviewed for different materials and machining methods.The purpose is to establish a FE model that is more in line with the real cutting conditions,and to provide the possibility for optimizing the cutting process variables.The development direction of FE simulation of metal cutting process is discussed,which provides guidance for future cutting process modeling.

关键词： Conventional and micro scale Finite element simulation Metal cutting process Micro cutting Modeling

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Research on Surface Roughness of Supersonic Vibration Auxiliary Side Milling for Titanium Alloy

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Chinese Journal of Mechanical Engineering 2022年第5期35卷 100-111页

作者： Xuetao Wei caixu yue Desheng Hu Xianli Liu Yunpeng Ding Steven Y.Liang Key Laboratory of Advanced Manufacturing and Intelligent Technology Ministry of EducationHarbin 150080China Department of Precision Manufacturing Engineering Suzhou Vocational Institute of Industrial TechnologySuzhou 215104China George W.Woodruff School of Mechanical Engineering Georgia Institute of TechnologyAtlanta 30332USA

The processed surface contour shape is extracted with the finite element simulation software.The difference value of contour shape change is used as the parameters of balancing surface roughness to construct finite element model of supersonic vibration milling in cutting stability domain.The surface roughness trial scheme is designed in the orthogonal test design method to analyze the surface roughness test result in the response surface methodology.The surface roughness prediction model is established and optimized.Finally,the surface roughness finite element simulation prediction model is verified by experiments.The research results show that,compared with the experiment results,the error range of the finite element simulation model is 27.5%–30.9%,and the error range of the empirical model obtained by the response surface method is between 4.4%and 12.3%.So,the model in this paper is accurate and will provide the theoretical basis for the optimization study of the auxiliary milling process of supersonic vibration.

关键词： Side milling Axial vibration Ultrasonic milling Finite element simulation Linear regression Surface roughness

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3D FEM Simulation of Milling Force in Corner Machining Process

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Chinese Journal of Mechanical Engineering 2017年第2期30卷 286-293页

作者： caixu yue Cui HUANG Xianli LIU Shengyu HAO Jun LIU State Engineering Laboratory of High Efficiency Cutting andTool Harbin University of Science TechnologyHarbin 50080China

To optimize milling force and machining accuracy quality in corner milling process, the changing law of milling force is revealed by Finite Element Method（FEM）. Based on DEFORM software a serial of 3D FEM models for corner milling process are devloped. Tool curved trajectory is achieved by establishing accurate relationship of tool location with milling time. Adaptive remeshing technique and iterative algorithm are adopted to ensure convergence of FEM model. Component force characteristics are revealed by analyzing FEM simulation results. It indicates that the milling force in Y direction becomes negative comparing with forces in X and Z direction. Magnitude of forces in three directions decreases with increase of spindle speed, while it increases with increase of milling feedrate. The simulation results for cutting force are in good agreement with those obtained from experiment. The FEM simulation model is first successfully established for corner milling process in this study, and the results provide a guide for optimizing cutting parameters in cutting process.

关键词： FEM simulation Corner milling Hardened steel Milling force

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A review of chatter vibration research in milling

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Chinese Journal of Aeronautics 2019年第2期32卷 215-242页

作者： caixu yue Haining GAO Xianli LIU Steven Y.LIANG Lihui WANG Harbin University of Science and Technology Georgia Institute of Technology KTH Royal Institute of Technology

Chatter is a self-excited vibration of parts in machining systems. It is widely present across a range of cutting processes, and has an impact upon both efficiency and quality in production processing. A great deal of research has been dedicated to the development of technologies that are able to predict and detect chatter. The purpose of these technologies is to facilitate the avoidance of chatter during cutting processes, which leads to better surface precision, higher productivity,and longer tool life. This paper summarizes the current state of the art in research regarding the problems of how to arrive at stable chatter prediction, chatter identification, and chatter control/-suppression, with a focus on milling processes. Particular focus is placed on the theoretical relationship between cutting chatter and process damping, tool runout, and gyroscopic effect, as well as the importance of this for chatter prediction. The paper concludes with some reflections regarding possible directions for future research in this field.

关键词： Chatter Gyroscopic effects Milling Process damping Tool runout

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Influences of Tool Wear on Residual Stress and Fatigue Life of Workpiece in Hard Cutting Process

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Journal of Harbin Institute of Technology(New Series) 2018年第5期25卷 61-69页

作者： caixu yue Lei Zhu Lei Feng Jun Liu Shengyu Hao Guangxu Ren School of Mechanical & Electrical Engineering Harbin Engineering University School of Mechanical & Power Engineering Harbin University of Science and Technology

Tool wear has an important influence on the residual stress distribution on the machined surface.Also,it will influence the fatigue life of finished workpiece. In this research,the hard turning process of hardened die steel Cr12 MoV was studied by using PCBN tool with considering tool wear. Based on the numerical treatment of residual stress,the dispersion and distribution curves of different tool wear were fitted,and the influence mechanism of tool wear on the residual stress distribution of machined surface was analyzed.Based on the theory of fatigue mechanics and mathematical statistics,the mathematical model for difference of stress dispersion and fatigue life was established. The rotating and bending tests were carried out on the standard parts after cutting process for the workpiece. The influence of tool wear on fatigue life was revealed by fracture surface morphology and fatigue life study. The results provide theoretical support for control of residual stress and the fatigue property of the machined surface under the actual working conditions.

关键词： hard turning process tool wear surface residual stress residual stress dispersion fatigue life

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智能刀具设计及关键技术研究进展

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航空制造技术 2024年第7期67卷 96-111页

作者：马尊严岳彩旭周天祥胡德生刘献礼哈尔滨理工大学先进制造智能化技术教育部重点实验室哈尔滨150080

随着“工业4.0”及“中国制造2025”战略计划的兴起,制造业中的智能制造及自动化水平不断提升,刀具作为生产过程中的重要一环,也变得更加精密化和智能化。智能刀具是实现智能制造和自动化生产的重要环节和必要保障,本文围绕智能刀具的... 详细信息

随着“工业4.0”及“中国制造2025”战略计划的兴起,制造业中的智能制造及自动化水平不断提升,刀具作为生产过程中的重要一环,也变得更加精密化和智能化。智能刀具是实现智能制造和自动化生产的重要环节和必要保障,本文围绕智能刀具的最新研究进展进行了详细论述,包括智能刀具设计、智能刀具关键技术、数字孪生技术及智能刀具系统等方面内容。归纳了国内外学者们在智能刀具集成优化与结构设计、智能刀具监测和调控技术、基于刀具管控和推荐的智能刀具系统的研究成果,简述了数字孪生技术在智能刀具领域中的应用,并指出了智能刀具目前存在的不足及未来发展方向。

关键词：智能刀具状态监测智能调控刀具管控数字孪生

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一株3,5,6-三氯-2-吡啶酚降解菌Delftia sp.DFT的分离鉴定及降解途径研究

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聊城大学学报（自然科学版） 2024年第2期37卷 89-100页

作者：贾楠岳彩旭吕雪茹王雪婷丁宁王圣惠聊城大学生命科学学院山东聊城252059

微生物降解是消除农药残留物3,5,6-三氯-2-吡啶酚(TCP)的有效方法,但其降解机制并不清楚。为探究TCP完整的代谢途径和降解机制。采用富集分离法从农田土壤中分离了一株TCP降解细菌,并分别通过高效液相色谱和液相色谱-质谱(LC-MS)技术检... 详细信息

微生物降解是消除农药残留物3,5,6-三氯-2-吡啶酚(TCP)的有效方法,但其降解机制并不清楚。为探究TCP完整的代谢途径和降解机制。采用富集分离法从农田土壤中分离了一株TCP降解细菌,并分别通过高效液相色谱和液相色谱-质谱(LC-MS)技术检测了菌株的降解性能,并鉴定了其代谢产物。该菌株为Delftia sp.DFT菌,它能在48 h内对50 mg/L的TCP降解率达34.28%,同时也能降解3,5-二氯-2-吡啶醇、6-氯-2-吡啶醇和2-羟基吡啶等其他氯代吡啶类化合物。在降解TCP过程中,共鉴定了12种不同的TCP代谢产物。初步推测水解-氧化脱氯途径、还原脱氯途径、反硝化及烷基化途径可能共同参与了菌株DFT对TCP的降解。据文献调研,这是首次在Delftia sp.菌中发现有四种可能的TCP代谢途径的报道,这为纯培养物中的TCP降解机制研究提供了参考信息。

关键词： 3,5,6-三氯-2-吡啶酚降解菌分离鉴定代尔夫特菌降解途径

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Adiabatic Shear Mechanisms for the Hard Cutting Process

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Chinese Journal of Mechanical Engineering 2015年第3期28卷 592-598页

作者： yue caixu WANG Bo LIU Xianli FENG Huize CAI Chunbin State Engineering Laboratory of High Efficiency Cutting and Tool Harbin University of Science and Technology

The most important consequence of adiabatic shear phenomenon is formation of sawtooth chip. Lots of scholars focused on the formation mechanism of sawtooth, and the research often depended on experimental approach. For the present, the mechanism of sawtooth chip formation still remains some ambiguous aspects. This study develops a combined numerical and experimental approach to get deeper understanding of sawtooth chip formation mechanism for Polycrystalline Cubic Boron Nitride（PCBN） tools orthogonal cutting hard steel GCr15. By adopting the Johnson-Cook material constitutive equations, the FEM simulation model established in this research effectively overcomes serious element distortions and cell singularity in high strain domain caused by large material deformation, and the adiabatic shear phenomenon is simulated successfully. Both the formation mechanism and process of sawtooth are simulated. Also, the change features regarding the cutting force as well as its effects on temperature are studied. More specifically, the contact of sawtooth formation frequency with cutting force fluctuation frequency is established. The cutting force and effect of cutting temperature on mechanism of adiabatic shear are investigated. Furthermore, the effects of the cutting condition on sawtooth chip formation are researched. The researching results show that cutting feed has the most important effect on sawtooth chip formation compared with cutting depth and speed. This research contributes a better understanding of mechanism, feature of chip formation in hard turning process, and supplies theoretical basis for the optimization of hard cutting process parameters.

关键词： adiabatic shear,FEM simulation,hard cutting process,sawtooth chip

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Hardening Effect on Machined Surface for Precise Hard Cutting Process with Consideration of Tool Wear

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Chinese Journal of Mechanical Engineering 2014年第6期27卷 1249-1256页

作者： yue caixu LIU Xianli MA Jing LIU Zhaojing LIU Fei YANG Yongheng State Engineering Laboratory of High Efficiency Cutting and Tool Harbin University of Science and Technology

During hard cutting process there is severe thermodynamic coupling effect between cutting tool and workpiece, which causes quenching effect on finished surfaces under certain conditions. However, material phase transformation mechanism of heat treatment in cutting process is different from the one in traditional process, which leads to changes of the formation mechanism of damaged layer on machined workpiece surface. This paper researches on the generation mechanism of damaged layer on machined surface in the process of PCBN tool hard cutting hardened steel Cr12MoV. Rules of temperature change on machined surface and subsurface are got by means of finite element simulation. In phase transformation temperature experiments rapid transformation instrument is employed, and the effect of quenching under cutting conditions on generation of damaged layer is revealed. Based on that, the phase transformation points of temperature under cutting conditions are determined. By experiment, the effects of cutting speed and tool wear on white layer thickness in damaged layer are revealed. The temperature distribution law of third deformation zone is got by establishing the numerical prediction model, and thickness of white layer in damaged layer is predicted, taking the tool wear effect into consideration. The experimental results show that the model prediction is accurate, and the establishment of prediction model provides a reference for wise selection of parameters in precise hard cutting process. For the machining process with high demanding on surface integrity, the generation of damaged layer on machined surface can be controlled precisely by using the prediction model.

关键词： precise hard cutting hardened mould steel hardening effect damaged layer on machined surface tool wear

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Research on Cutting Force Modeling and Surface Qualityin the Transition Area of the Mosaic Mold

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振动．测试与诊断 2018年第3期38卷 632-646页

作者： LIU Xianli GAO Haining yue caixu JIANG Nan School of Mechanical and Power Engineering Harbin University of Science and Technology Harbin 150080 China

Aiming at the problem of tool wear and breakage, the low accuracy of machined surface duringthe milling process of automobile panel splicing dies, the cutting force modeling of micro element is carriedout. The cutting chip thickness of each cutting cycle is built as a function of the cutting angle and the shearforce according to the different hardness of machining materials, and a plow force model are obtained underng angles. By introducing a single degree of freedom italic collision model, the Hopkinsontest is used to obtain the elastic deformation δ of the tool workpiece impact under different spindle speeds,sults showforce on the tool in the transition area is obtained. Combining above models together,of milling force in the transition area can be obtained. Experiment and simulation reconslstendirections is studied. Fromcythto prove the accuracy of the model. The surface quality under different feede analysis results of machined surface quality, surfacedifference between workpieces, it is concluded that better surface quality can be obtaineness and heightness and low hardness workpiece. The results provide theoretical support for the optimizationing process in the splicing die of the automobile panel highof the milling process in the splicing die of the automobile panel.

关键词： splicing die impact force model cutting force model surface quality

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