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Numerical modeling of wear in orthogonal cutting of multilayer coated tools

Procedia CIrP 2021年 102卷 67-72页

作者： Grégory Methon Cédric Courbon rachid M’Saoubi Mathieu Girinon Joël rech University of Lyon Ecole Centrale de Lyon - ENISE LTDS CNRS UMR 5513 58 Rue Jean Parot 42000 Saint-Etienne France R&D Material and Technology Development Seco Tools AB SE-73782 Fagersta Sweden CETIM 52 avenue Félix-Louat 60300 Senlis France

The present work aims at improving tool wear simulation in orthogonal turning operations by considering local wear properties at the scale of the coating. A multi-step procedure developed in previous studies is first employed to predict cutting tool wear by combining a pure thermal model to an Arbitrary-Lagrangian-Eulerian (ALE) thermomechanical sub-model in order to predict the thermomechanical loadings applied onto the tool. The tool geometry is updated by moving the tool nodes, taking into account the local contact pressure, sliding velocity and temperature. The key improvement of this paper is to implement a specific wear model for each of the coating layer and substrate depending on the current position of each node at the contact interface. A comparative study is performed between the homogenous wear equation and the improved multi-layer model. This work highlights that an adaptive wear rate calculation based on nodal position has to be considered to achieve an actual predictive model.

关键词： Turning Wear Coatings

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Investigation on cutting fluid use in finish milling of polylactide (PLA) 3d-printed parts

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Procedia CIrP 2025年 133卷 656-661页

作者： Margaux Lorenzoni Laurent Spitaels Edouard rivière-Lorphèvre Jérémy Odent rachid M’Saoubi Liam Cloëz Michaël Fontaine François ducobu Machine Design and Production Engineering Lab – Research Institute for Materials Science and Engineering University of Mons Place du Parc 20 7000 Mons Belgium Laboratory of Polymeric and Composite Materials (LMPC) – Center of Innovation and Research in Materials and Polymers (CIRMAP) University of Mons Place du Parc 20 7000 Mons Belgium R&D Material and Technology Development Seco Tools AB Björnbacksvägen 2 SE-737 82 Fagersta Sweden Department of Mechanical Engineering Sciences - Division of Production and Materials Engineering Lund University Ole Römers väg 1 SE-221 00 Lund Sweden FEMTO-ST Institute – Applied Mechanics Dept. Université de Franche-Comté – SUPMICROTECH – CNRS Rue de l’épitaphe 24 F-25000 Besançon France

Fused Filament Fabrication (FFF) is an additive manufacturing process based on material Extrusion (MEX) of polymeric filament. This manufacturing technology is commonly used for personalized production applications and prototyping, allowing to obtain customized parts with complex geometries at a low cost. However, this production technique has its limitations regarding dimensional accuracy and surface roughness of the final parts. To overcome these limitations, finish milling is considered to be a promising technique as it is widely used for metallic parts. Yet, the specific thermal properties of polymers such as low thermal conductivity and low melting temperature are adding a challenge in the determination of optimal cutting conditions. In this context, the use of cutting fluid could be the key to keep the material from melting during milling. Therefore, this paper proposes to compare the impact of using a compressed air flow to dry conditions on the cutting forces and the surface quality obtained on 3d-printed polylactide (PLA) parts. The qualification test of the tool-material couple standard (NF E 66-520-6) will be used as a guideline to determine the relevance of cutting fluid use for cutting conditions varying around an operating point. Moreover, simulated cutting forces using a mechanistic model will be compared to experimental data to evaluate the applicability of the model.

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Visualising Microstructural dynamics of Titanium Aluminium Nitride Coatings Under High-Temperature Oxidation

SSRN

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SSrN 2022年

作者： Makgae, Ofentse A. Lenrick, Filip Bushlya, Volodymyr Andersson, Jon M. M'Saoubi, rachid Ek, Martin NanoLund NanoLund Lund University Box 118 Lund22100 Sweden Centre for Analysis and Synthesis Lund University Box 124 Lund22100 Sweden Division of Production and Materials Engineering Lund University Box 118 Lund22100 Sweden R&D Materials and Technology Development Seco Tools AB Fagersta737 82 Sweden

Understanding the link between titanium-aluminium nitride’s (Ti1-xAlxN) physicochemical properties and structural dynamics during operation is essential to designing and fabricating advanced ceramic coatings. Herein we directly visualise the oxidation of Ti1-xAlxN (for x = 0, 0.18, 0.44, & 0.67) coatings from 100 to 1000 °C using environmental transmission electron microscopy and energy dispersive X-ray analysis. The high-frame-rate ETEM movies show that oxidation in TiN proceeds at the grain boundaries and cracks;in contrast, Ti1-xAlxN coatings transform from large as-deposited grains into oxide nanoparticles. Moreover, high-resolution ETEM imaging showed the presence of anatase TiO2 at the early stages of oxidation across all compositions. above ~850 °C, the oxide nanoparticles grow through crystal merging, diffusion and recrystallisation to form rutile TiO2. The EdX elemental maps coupled with secondary electron imaging reveal a uniform TiO2 sublayer decorated with increasing coverage of Al2O3 particles for x = 0.18 to 0.44. In contrast, coatings with x = 0.67 reveal a complete in-plane phase separation of Al- and Ti-oxides, which can rationalise their decreasing long-term oxidation resistance. Finally, the study provides unique insight into the real-time structural dynamics underpinning the oxidation resistance of Ti1-xAlxN coatings. © 2022, The Authors. All rights reserved.

关键词： Titanium dioxide

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Optimization-based procedure for the determination of the constitutive model coefficients used in machining simulations

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Procedia CIrP 2019年 82卷 374-378页

作者： Wenyu Cheng José Outeiro Jean-Philippe Costes rachid M’Saoubi Habib Karaouni Stefan dietrich Bertand Marcon Pedro rosa Arts et Metiers ParisTech LaBoMaP Rue Porte de Paris 71250 Cluny France R&D Material and Technology Development Seco Tools AB SE-73782 Fagersta Sweden Safran Tech Research and Technology Center 78772 Magny-Les-Hameaux France Karlsruhe Institute of Technology Institute for Applied Materials (IAM-WK) Kaiserstraße 12 76131 Karlsruhe Germany IDMEC Instituto Superior Técnico Universidade de Lisboa Av. Rovisco Pais N1 1049-001 Lisboa Portugal

This paper deals with the determination of the constitutive model coefficients used in machining simulations. An optimization-based procedure is developed and applied to constitutive model coefficients determination of Ti6Al4V titanium alloy. The procedure is implemented in LS-dyna/LS-Opt software, coupled with abaqus/Explicit to calculate the force-displacement curve at each iteration, which is required for the optimization-based procedure. The robustness of the procedure to determine the constitutive model coefficients is evaluated by comparing the predicted and measured plastic strain distributions in the samples.

关键词： Modelling Machining Constitutive model

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An inverse problem for retrieving time dependency of heat flux in metal cutting via linear programming

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Procedia Manufacturing 2018年 25卷 287-293页

作者： V. Kryzhanivskyy O. Shupikov V. Bushlya O. Gutnichenko M. Hörndahl r. M’Saoubi J.-E. Ståhl Division of Production and Materials Engineering Lund University Ole Römers väg 1 Lund 22100 Box-118 Sweden Department of Software Engineering Zhytomyr State Technological University Chernyakhovsky 103 Zhytomyr 10013 Ukraine R&D Materials and Technology Development Seco Tools AB SE-73782 Fagersta Sweden

The paper addresses the inverse heat transfer problem, in which the dependence of the flux on time is determined on the basis of the measured temperatures in remote points of the tool body. The nonlinear heat equation is considered since the properties of the tool material are temperature-dependent. The machining time interval is divided into subintervals within which the change in the tool material properties is ignored. Therefore, it possible to consider a sequence of linear programming problems, each of which minimizes the maximum deviation of the measured temperatures from the calculated ones.

关键词： Tool temperature inverse heat transfer problem heat flux

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Constitutive model incorporating the strain-rate and state of stress effects for machining simulation of titanium alloy Ti6Al4V

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Procedia CIrP 2018年 77卷 344-347页

作者： Wenyu Cheng Jose Outeiro Jean-Philippe Costes rachid M’Saoubi Habib Karaouni Lamice denguir Viktor Astakhov François Auzenat Arts et Metiers ParisTech LaBoMaP Rue Porte de Paris 71250 Cluny France R&D Material and Technology Development Seco Tools AB SE-73782 Fagersta Sweden Safran Tech Research and Technology Center 78772 Magny-Les-Hameaux France Production Service Management Inc. (PSMi) Saline MI USA R and D milling and process 22 avenue de la prospective 18020 bourges cedex

Ti6Al4V titanium alloy is widely used in aero-engines due to its superior performance. However, as a difficult-to-cut alloy, it induces short cutting tool life and poor surface integrity. To improve these process outcomes, numerical simulations are of importance. The predictive ability of such simulation depends on the accuracy of the constitutive model which describes the work material behavior under loading conditions specific to metal cutting. Therefore, the focus of this paper is the formulation of a constitutive model to be used in the orthogonal cutting simulation of Ti6Al4V. The distinguished feature of this model is its simplicity, accounting for the strain-rate and state of stress effects in the work material deformation and fracture. The model coefficients were identified using mechanical tests and numerical simulations with specially-designed test specimens to cover a wide range of strain-rates and state of stress. Orthogonal cutting simulations were performed and the obtained results were compared with those measured.

关键词： Constitutive model Metal cutting simulation State of stress

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Machinability of Powder Metallurgy Steels Using PcBN Inserts

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Procedia CIrP 2014年 14卷 83-88页

作者： rachid M'Saoubi Tobias Czotscher Olof Andersson daniel Meyer R&D Material and Technology Development Seco Tools AB Björnbacksvägen 02 SE-73782 Fagersta Sweden Foundation Institute of Materials Science (IWT) Badgasteiner Str. 3 D-28359 Bremen Germany Höganäs AB Bruksgatan 35 SE-263 83 Höganäs

Primary manufacturing of steels by powder metallurgy (PM) is of increasing interest for a wide range of industrial applications. Especially in automotive parts and tools, PM materials are utilized, as they show advantageous behavior regarding chemical, mechanical and functional properties as well as resource efficiency. Consequently, machining of these materials is an emerging topic for both, industry and science. This paper addresses the machinability of PM steels. Two PM high speed steels (HSS) were characterized and machined varying the machining parameters and edge preparation (PcBN inserts) in longitudinal and orthogonal hard turning. Furthermore, the influence of manganese sulfides (MnS) in the PM material was analyzed by comparing experiments applying alloys with defined content of MnS. Besides tool life and achievable surface roughness, the surface integrity was assessed. The results reveal that the amount and shape of carbides as well as the porosity of the PM steels play an important role in the wear mechanism when machining this kind of materials. As expected, addition of MnS leads to a decrease of cutting forces and allows for significantly higher tool life. The influence of machining parameters and the tool edge geometry is discussed. Based on the results, suitable cutting conditions for machining of PM steels can be derived.

关键词： Machinability Cutting Steel PM Steel

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Machining Behaviour of Ti-6Al-4 V and Ti-5553 All0oys in Interrupted Cutting with PVd Coated Cemented carbide

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Procedia CIrP 2012年 1卷 202-207页

作者： Asier Ugarte rachid M'Saoubi Ainhara Garay P.J. Arrazola R&D Materials and Technology DevelopmentProcesses Seco Tools AB Fagersta SE-73782 Sweden Manufacturing Department Faculty of Engineering Mondragon University Mondragon Spain

Machining behaviour of Ti-5553, Ti-6Al-4 V mill-annealed (MA) and Ti-6Al-4 V solution treated and aged (STA) alloys was studied in different interrupted cutting operations using PVd coated cemented carbide tools. Single tooth face milling was employed to study the wear behaviour and tool life of the coated tools that were further inspected using scanning electron microscopy. The results indicated that a poor machinability was observed for Ti-5553 when compared to Ti-6Al-4 V (STA) and Ti6Al-4 V (MA). This was found to correlate reasonably well with an increase of work material adhesion severity on the cutting tool that resulted in an increased chipping and led to catastrophic tool failure. Series of orthogonal interrupted cutting tests were performed subsequently to investigate the role of work material and cutting data on the chip formation, mechanical loads and frictional conditions at the tool-chip contact. A detailed analysis of the chip segmentation characteristics of the different Ti alloys is provided and the results are employed in different analytical models to assess the shear strain, strain rate and segmentation frequency. Finally, a comparison of Ti-5553 and Ti-6-4 (MA) in interrupted turning is presented where the differences in terms of cutting temperature are discussed.

关键词： Machining Interrupted cutting Titanium alloys Ti-6Al-4 V Ti-5553

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