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19th CIRP Conference on Modeling of Machining Operations, CMMO 2023

作者： Ducobu, François Palanisamy, Nithyaraaj Kugalur Arrazola, Pedro-José Rivière-Lorphèvre, Edouard Machine Design and Production Engineering Lab Research Institute for Science and Material Engineering University of Mons Mons7000 Belgium Mechanical and Manufacturing Department Faculty of Engineering Mondragon Unibertsitatea Loramendi 4 Arrasate-Mondragón20500 Spain

The identification of input parameters for funite element modelling of the cutting process is still a complex task as the experimental testing equipment cannot reach its combined levels of strains, strain rates and temperatures. Inverse identification using Artificial Intelligence method provides a relevant alternative. In this paper, material constitutive and friction models parameters identified with an Efficient Global Optimization algorithm and an ALE orthogonal cutting model are introduced in a CEL model. Assessment of the differences in the results due to the formulation and dependence of parameters identification to the finite element model are then performed. © 2023 Elsevier B.V.. All rights reserved.

关键词： Finite element method

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Mechanistic modeling of cutting forces in milling of unidirectional Glass Fiber Reinforced Polymer (UD-GFRP) 20

Mechanistic modeling of cutting forces in milling of unidire...

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

作者： Nutte, Matthias Rivière-Lorphèvre, Edouard Dambly, Valentin Arrazola, Pedro-José Lazoglu, Ismail Granjon, Aurélie Ducobu, François Machine Design and Production Engineering Lab Research Institute for Science and Material Engineering UMONS Mons7000 Belgium Mechanical and Manufacturing Department Faculty of Engineering Mondragon Unibertsitatea Loramendi 4 Arrasate-Mondragón20500 Spain Manufacturing and Automation Research Center Koc University Istanbul34450 Turkey Sobelcomp SPRL Rue de l'économie 13 Loncin 4431 Belgium

Mechanistic models, established on experimental data, are recognized for their precision and simplicity in implementation. In this context of milling, the modeling of cutting forces, specifically radial and tangential components, has been extensively explored for unidirectional carbon fiber-reinforced polymer (UD-CFRP) parts. These models account for the anisotropic nature of fiber-reinforced polymers (FRPs), with cutting coefficients that vary based on the instantaneous cutting angle. However, due to the inherent flexibility of these materials, primarily attributed to their low thickness, axial cutting forces must also be incorporated to accurately represent the phenomena occurring during the machining process. This study develops a model for calculating cutting forces in three spatial directions for UD-GFRPs (unidirectional Glass Fiber-reinforced polymers). Building on an existing model from the literature for UD-CFRP, this new version introduces several modifications. First, the model validated for CFRPs must be extended to GFRPs. Secondly, the model must be extended from two dimensions to three dimensions. Finally, to ensure that the model includes only the actual contributions of the trimming operation, machining tests will be performed using only the rolling teeth. The cutting coefficients are modelled as a periodic function with a fundamental period of π. A first-order Fourier series was chosen for this purpose. Fourier series parameters are identified from the milling forces measured during a set of slotting operations at three feed rates and four fiber orientations. While the average levels of cutting forces are accurately modelled for both slotting and shoulder milling (with 50% immersion in up milling), the modeling of force amplitudes still requires improvement. © 2025 The Author(s).

关键词： Slotting

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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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Use of the CEL method for estimating the minimum chip thickness when orthogonal cutting Ti6Al4V 21

Use of the CEL method for estimating the minimum chip thickn...

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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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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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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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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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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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Mechanistic modeling of cutting forces in milling of unidirectional Glass Fiber Reinforced Polymer (UD-GFRP)

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Procedia CIRP 2025年 133卷 424-429页

作者： Matthias Nutte Edouard Rivière-Lorphèvre Valentin Dambly Pedro-José Arrazola Ismail Lazoglu Aurélie Granjon François Ducobu Machine Design and Production Engineering Lab Research Institute for Science and Material Engineering UMONS Mons 7000 Belgium Mechanical and Manufacturing Department Faculty of Engineering Mondragon Unibertsitatea Loramendi 4 Arrasate-Mondragón 20500 Spain Manufacturing and Automation Research Center Koc University Istanbul 34450 Turkey Sobelcomp SPRL. Rue de l’économie 13 4431 Loncin Belgium

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The CDIO approach in a fablab activity for engineering education promotion 48

The CDIO approach in a fablab activity for engineering educa...

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48th Annual Conference on Engaging engineering Education, SEFI 2020

作者： Wattiaux, David Leroy, Cédric Olivier, Bryan Demarbaix, Anthonin Department of Theoretical Mechanics Dynamics and Vibrations Faculty of Engineering University of Mons Mons Belgium Machine Design and Production Engineering Lab Faculty of Engineering - University of Mons Mons Belgium

ISBN: (纸本)9782873520205

The number of Fablabs has been steadily increasing over the last few years. Their main objectives are to sensitize its public on Science, Technology, engineering, and Math (STEM) education through the digital manufacturing chain of an object and to allow the large public to make their own objects. Through, the increasing popularization of these advanced technologies, it becomes more difficult to establish the makers from the engineers. The thinness of this distinction may have, in some cases, a negative impact on the promotion of engineering education. In actual engineering projects, a rigorous approach is usually followed such as the CDIO method. Meanwhile, the design rules pursued by the makers are not necessarily as systematic as the ones followed by the engineers. In order to present this distinction to high school students, this paper illustrates the usage of a CDIO approach within the framework of a Fablab activity to promote engineering education. The proposed week-long activity concerns a personal loudspeaker construction using the resources and capabilities of a Fablab. Furthermore, due to a precise number of turns in the windings, the manual construction of the speaker remains a considerably laborious task. To solve this issue, the students are made responsible for proposing an innovative solution by applying a CDIO approach. This solution must lead to the design of a machine-tool manufacture dedicated to a loudspeaker production. © 2020 SEFI 48th Annual Conference Engaging engineering Education, Proceedings. All rights reserved.

关键词： engineering education

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