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21st International Conference of the European Society for Precision engineering and Nanotechnology, EUSPEN 2021

作者： Ducobu, François Arrazola, Pedro-José Aristimuño, Patxi Machine Design and Production Engineering Lab. Faculty of Engineering The University of Mons Mons Belgium Mondragon University Faculty of Engineering Mechanical and Manufacturing Department Mondragon Spain

ISBN: (纸本)9780995775190

The production of micro-components or macro-components with micro-features requires adaptions of their manufacturing process. When micro-machining, the dimensions of the tool, but also some cutting parameters are reduced. Indeed, to avoid breaking the tool due to too large cutting forces, a reduction of the feed is required. This leads to the minimum chip thickness phenomenon in which no chip is formed if the feed is too small by comparison to the cutting edge radius. The determination of the minimum chip thickness value is of great importance for the practitioner. In this work, a finite element modelling approach is followed to investigate the minimum chip thickness in the orthogonal cutting configuration for the Ti6Al4V titanium alloy. The material removal process is modelled with the Coupled Eulerian-Lagrangian (CEL) approach to avoid any mesh distortion. The model allows studying the cutting mechanisms when the uncut chip thickness reduces to reach values as small as the uncut chip thickness and even below it. With the model, the minimum chip thickness value is estimated for Ti6Al4V and the considered cutting conditions. The influence of the uncut chip thickness on the cutting forces, their ratio and the specific cutting energy are also considered. These numerical results are then compared to orthogonal cutting experiments carried out in the same conditions to validate them. © 2021 Proceedings of the 21st International Conference of the European Society for Precision engineering and Nanotechnology, EUSPEN 2021. All rights reserved.

关键词： Aluminum alloys

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Development of a novel benchmark artifact for Additive Manufacturing processes 21

Development of a novel benchmark artifact for Additive Manuf...

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21st International Conference of the European Society for Precision engineering and Nanotechnology, EUSPEN 2021

作者： Spitaels, Laurent Rivière-Lorphèvre, Edouard Demarbaix, Anthonin Ducobu, François Machine Design and Production Engineering Lab. Faculty of Engineering University of Mons Place du parc 20 Mons7000 Belgium

ISBN: (纸本)9780995775190

Additive Manufacturing (AM) allows generation of geometrically complex parts which cannot be obtained by conventional processes (machining, forging, casting e.g.). It also enables production of near net shape parts requiring few finishing operations before use (roughness reduction e.g.). Mastering geometrical and dimensional accuracy of additively manufactured parts is then mandatory to ensure their functionality. In conventional processes, dimensional accuracy of different machines or process conditions (hard machining vs super finishing e.g.) can be objectively compared using the International Tolerance (IT) grades defined by the International Standard Organization (ISO) in ISO 286-1 GPS standard (Geometrical Product Specifications). Required geometrical accuracy can be specified using ISO 1101. In the specific case of blank produced by machining operations, ISO 2768-1 is often used for dimensional tolerancing and ISO 2768-2 for geometrical tolerancing. In the case of Additive Manufacturing, neither dimensional and geometrical tolerancing standard nor benchmarking method standard exist. The solution proposed by many authors is to develop their own benchmark artifact to evaluate the dimensional and geometrical accuracy of their machine, their minimal achievable detail size as well as their capability to replicate a given shape within a given International Tolerance grade. This article aims to make a review of the existing benchmark artifacts and to summarize the main requirements chosen by authors. From this state of the art, a new benchmark artifact is proposed by adapting an existing one to fulfil its missing characteristics. Measurements possibilities in terms of dimensions are enumerated and organized using ISO 286 dimensional intervals as presented in the literature. Geometrical evaluation possibilities are also listed and enumerated. It is then applied to a part obtained by Fused Deposition Modelling (FDM). © 2021 Proceedings of the 21st International Confere

关键词： Benchmarking

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Influences of cutting speed and material constitutive models on chip formation and their effects on the results of Ti6Al4V orthogonal cutting simulation 24

Influences of cutting speed and material constitutive models...

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24th International ESAFORM Conference on Material Forming, ESAFORM 2021

作者： Kugalur-Palanisamy, Nithyaraaj Rivière-Lorphèvre, Edouard Arrazola, Pedro-José Ducobu, François University of Mons Faculty of Engineering Machine Design and Production Engineering Lab Belgium Belgium Mondragon University Faculty of Engineering Mechanical and Manufacturing Department Spain

ISBN: (纸本)9782870193020

The highly used Ti6Al4V alloy is a well know hard-to-machine material. The modelling of orthogonal cutting process of Ti6Al4V attract the interest of many researchers as it often generates serrated chips. The purpose of this paper is to show the significant influence of cutting speed on chip formation during orthogonal cutting of Ti6Al4V along with different material constitutive models. Finite element analyses for chip formation are conducted for different cutting speeds and are investigated with well-known Johnson-Cook constitutive model, a modified Johnson-Cook model known as Hyperbolic Tangent (TANH) model that emphasizes the strain softening behavior and modified Johnson-Cook constitutive model that consider temperature dependent strain hardening factor. A 2D Lagrangian finite element model is adopted for the simulation of the orthogonal cutting process and the results from the simulations such as calculated forces, chip morphologies are analyzed and are compared with the experimental results to highlight the differences. The results analysis shows that, the temperature in the secondary deformation zone is directly proportional to the cutting speed. © ESAFORM 2021 - 24th Inter. Conf. on Mat. Forming. All rights reserved.

关键词： Constitutive models

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Simulation of chip formation for varying uncut chip thickness during vibration-assisted drilling with the CEL method

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Procedia CIRP 2025年 133卷 376-381页

作者： L. Schumski F. Ducobu L. Langenhorst J. Sölter B. Karpuschewski Leibniz Institute for Materials Engineering IWT Badgasteiner Straße 3 28359 Bremen Germany University of Bremen MAPEX Center for Materials and Processes Bibliothekstraße 1 28359 Bremen Germany University of Mons (UMONS) Faculty of Engineering (FPMs) Machine Design and Production Engineering Lab 20 Place du Parc B-7000 Mons Belgium

Vibration-assisted drilling is particularly efficient for long-chipping and difficult-to-machine materials due to its special kinematics with interrupted cutting. In order to optimize the process, a deeper understanding of the occurring external and internal material loads is required. For this purpose, a model is developed and simulation results are compared with experimental data on the materials Ti6Al4V and AISI 4140. Based on a kinematic simulation, individual segments on the main cutting edge are considered and the local chip formation is modelled as an orthogonal cut using the CEL method. Special consideration is given to the process kinematics, where, in addition to the entry and exit of the tool cutting edge, a varying uncut chip thickness occurs. Drilling without vibration assistance is also modelled in this way. The resulting drilling torques and thrust forces are compared with experimental data. The experiments are carried out on tubes with different internal diameters to represent the different segments of the main cutting edge. In addition, experimental results on drilling a rod and into solid material quantify the effects of the chisel edge and the minor cutting edges. The results show that both drilling and vibration-assisted drilling can be modelled using orthogonal cutting models with acceptable computation times.

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Finite element modelling of the Taylor impact test in 3D with the Coupled Eulerian-Lagrangian method 24

Finite element modelling of the Taylor impact test in 3D wit...

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24th International ESAFORM Conference on Material Forming, ESAFORM 2021

作者： Ducobu, François Demarbaix, Anthonin Pantalé, Olivier Machine Design and Production Engineering Lab Faculty of Engineering University of Mons Belgium Université de Toulouse INP-ENIT Tarbes France

ISBN: (纸本)9782870193020

When modelling a cutting operation, the constitutive model of the machined material is one of the key parameters to obtain accurate and realistic results. Up to now, the Johnson-Cook model is still the most used, even if an increasing number of models, such as the Hyperbolic TANgent (TANH) model, were introduced last years to overcome its limitations and come closer to the actual material behaviour. Experimental tests on dedicated equipment are usually required to identify the parameters of the constitutive models. This paper introduces the Coupled Eulerian-Lagrangian (CEL) formalism to model in 3D the Taylor impact test, one of the common tests to perform that parameters identification. Indeed, one identification way involves modelling the test to determine the constitutive model parameters by comparing the experimental and the numerical samples geometries. The developed CEL model is validated against a Lagrangian reference model for a steel alloy and the Johnson-Cook constitutive model. The main goal of using the CEL method is to get rid of the elements distortion due to the high strains and strain rates during the test. Mesh dependence of the results is highlighted and a recommendation is provided on the mesh to adopt for future work. The CEL model of the 3D Taylor impact test is then extended to the use of the TANH model. The results are finally compared with that of the Johnson-Cook constitutive model. © ESAFORM 2021 - 24th Inter. Conf. on Mat. Forming. All rights reserved.

关键词： Constitutive models

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Surface finishing of EBM parts by (electro-)chemical etching 6th

Surface finishing of EBM parts by (electro-)chemical etching

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6th CIRP Conference on Surface Integrity, CSI 2022

作者： Spitaels, Laurent Rivière-Lorphèvre, Édouard Díaz, MacArena Cantero Duquesnoy, Jonathan Ducobu, François Machine Design And Production Engineering Lab Research Institute For Science And Material Engineering University Of Mons Place du Parc 20 Mons7000 Belgium Chimiderouil S.A. Rue des Ayettes 20 Ghlin 7011 Belgium

Post treatment of titanium alloy parts obtained by Electron Beam Melting (EBM) is required before assembly due to their high roughness (Ra = 25 μm). For parts with complex geometry, chemical and electro-chemical etching are two promising processes which enhance the part surface integrity thanks to their global action. These two processes were applied to Ti6Al4V parts obtained by EBM. Their surface topography, micro hardness, dimensional and geometrical accuracy were compared. For a given removed thickness of 0.150 mm, electro-chemical etching exhibited higher efficiency to improve arithmetic roughness (∼39%) than chemical etching (∼7%). © 2022 The Authors.

关键词： Microhardness

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Investigation on cutting fluid use in finish milling of polylactide (PLA) 3D-printed parts 20

Investigation on cutting fluid use in finish milling of poly...

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20th CIRP Conference on Modeling of Machining Operations in mons, CIRP CMMO 2025

作者： Lorenzoni, Margaux Spitaels, Laurent Rivière-Lorphèvre, Edouard Odent, Jérémy M'Saoubi, Rachid Cloëz, Liam Fontaine, Michaël Ducobu, François Machine Design and Production Engineering Lab Research Institute for Materials Science and Engineering University of Mons Place du Parc 20 Mons7000 Belgium University of Mons Place du Parc 20 Mons7000 Belgium R&D Material and Technology Development Seco Tools AB Björnbacksvägen 2 FagerstaSE-737 82 Sweden Department of Mechanical Engineering Sciences Division of Production and Materials Engineering Lund University Ole Römers väg 1 LundSE-221 00 Sweden FEMTO-ST Institute-Applied Mechanics Dept. Université de Franche-Comté-SUPMICROTECH-CNRS Rue de l'épitaphe 24 BesançonF-25000 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. © 2025 The Authors.

关键词： Compressed air

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Dimensional and geometrical performance assessment of two FDM printers using a benchmark artifact 22

Dimensional and geometrical performance assessment of two FD...

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22nd International Conference of the European Society for Precision engineering and Nanotechnology, EUSPEN 2022

作者： Spitaels, Laurent Rivière-Lorphèvre, Edouard Demarbaix, Anthonin Thielens, Vincent Ducobu, François Machine Design and Production Engineering Lab Research Institute for Science and Material Engineering University of Mons Place du Parc 20 Mons Belgium Science and Technology Research Unit Science and Technology Department Condorcet - Hainaut Provincial High School Square Hiernaux 2 Charleroi Belgium

ISBN: (纸本)9781998999118

Additive Manufacturing (AM) is a promising process allowing the generation of complex geometries in near net shape. Standards are under development in a joint effort between ASTM and ISO to facilitate the use of AM processes in the industry. However, some areas of interest, for assessing dimensional and geometrical performances of AM printers, are still not covered. In this article, dimensional and geometrical performances of two Fused Deposition Modelling (FDM) printers with Cartesian architecture (Ultimaker S3 and Intamsys FUNMAT HT) are compared using an original benchmark artifact design. Five parts were printed on each printer in ABS. Five other parts were also produced with the Ultimaker S3 in PLA to show the influence of material choice on the printer's dimensional and geometrical performances. Intervals of tolerances (IT) were determined using the ISO 286-1 method. Both machines can lead to an IT between 10 and 15 depending on the size of the measured features. In terms of geometrical deviations, coaxiality was the highest deviation observed on both printers with average values between 0.376 mm and 0.679 mm for the Ultimaker S3 in PLA and ABS, while the FUNMAT HT can reach values of 0.759 mm in ABS. The FUNMAT HT exhibits a better homogeneity of computed IT according to its X and Y axes, while lower performances according to the Z axis were observed compared to the Ultimaker S3. In terms of geometrical performances, the FUNMAT HT has a lower ability than the Ultimaker S3 to reproduce features according to the Z axis. Except for this category, other geometrical features were more accurately reproduced with the Intamsys printer on a global level. The material choice also has a slight influence both on the dimensional and geometrical performances of the Ultimaker S3. © European Society for Precision engineering and Nanotechnology, Conference Proceedings - 22nd International Conference and Exhibition, EUSPEN 2022. All rights reserved.

关键词： Benchmarking

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An experimental methodology to improve the robotic drilling of aluminium alloys

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CIRP Annals 2025年

作者： Ducobu, François Beuscart, Thomas Dambly, Valentin Rivière-Lorphèvre, Edouard Ortiz-de-Zarate, Gorka Arrazola, Pedro-José Machine Design and Production Engineering Lab Research Institute for Science and Material Engineering UMONS Belgium Faculty of Engineering Department of Mechanics and Industrial Production Mondragon Unibertsitatea Spain

In aeronautics, mastering the drilling process is crucial to meet strict quality standards. While robots provide a cost-effective solution for drilling large, complex parts, challenges arise in metallic materials due to their low stiffness. This study establishes a systematic experimental method to improve hole quality during robotic drilling of aluminium alloys. Holes were drilled in plates in four positions and 64 postures using a 6 mm tool to analyse their influence on a new defect index. A static deflection compensation method was developed to improve hole quality, addressing static deflection issues narrowing the gap between robotic drilling and CNC machining. © 2025 CIRP

关键词： Aluminum alloys

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Development and experimental validation of a macroscopic analytical model aiming to generate metal-FRP stacks drilling cutting force and torque 24

Development and experimental validation of a macroscopic ana...

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24th International ESAFORM Conference on Material Forming, ESAFORM 2021

作者： Beuscart, Thomas Arrazola, Pedro-José Rivière-Lorphèvre, Edouard Ducobu, François Machine Design and Production Engineering Lab Faculty of Engineering University of Mons Place du Parc 20 Mons7000 Belgium Escuela Politécnica Superior de Mondragon Uniberstitatea Loramendi 4 Mondragon20500 Spain

ISBN: (纸本)9782870193020

Composites materials and especially FRP are increasingly employed in many fields of applications (transport, aerospace, …) due to the current trend of improving global energy performances of new designs notably by mass saving. However the use of metallic materials such as aluminum and titanium alloys is still necessary in many cases and a lot of structures are made of a dual technology called stacks (panels composed of different layers of FRP and metal bounded together). Combining the different properties of these materials offers many advantages regarding the mechanical and structural aspects. This is nevertheless for the same reason that machining and especially drilling stacks is a laborious task: the tools and cutting conditions are way too divergent to avoid vibrations, problems of dimensional tolerances and delamination of the composite. The knowledge and characterization of the drilling cutting forces is a first step to solve these issues. The purpose of this article is to provide an accurate macroscopic analytical model fitted for stacks and compare it quantitatively with experimental tests. The given model is divided in two parts (i.e. respectively adapted for the two materials) and is based on the discretization of the cutting edge. The proposed algorithm is able to predict accurately drilling force and torque along time in function of the cutting conditions, the tool and material configurations. A reverse least squared method is used to obtain the empirical input parameters, allowing to minimize the number of experimental drilling tests to obtain the empirical input parameters. © ESAFORM 2021 - 24th Inter. Conf. on Mat. Forming. All rights reserved.

关键词： Metals

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