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UNIVERSITI TEKNIKAL MALAYSIA MELAKA
MACHINING SIMULATION OF COMPOSITE MATERIALS USING ENGINEERING SIMULATION SOFTWARE
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Manufacturing Design) (Hons.)
by
ZAMMERI BIN ABD RAHMAN
B051010253
801205-11-5021
FACULTY OF MANUFACTURING ENGINEERING
2014
MACHINING SIMULATION OF COMPOSITE
MATERIALS USING ENGINEERING SIMULATION
SOFTWARE
ZAMMERI BIN ABD RAHMAN
B051010253
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
2014
UNIVERSITI TEKNIKAL MALAYSIA MELAKA
BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA
TAJUK: Machining Simulation of Composite Materials Using Engineering Simulation Software SESI PENGAJIAN: 2013/14 Semester 2 Saya ZAMMERI BIN ABD RAHMAN mengaku membenarkan Laporan PSM ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut: 1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan
untuk tujuan pengajian sahaja dengan izin penulis. 3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan
pertukaran antara institusi pengajian tinggi. 4. **Sila tandakan ( )
SULIT
TERHAD
TIDAK TERHAD
(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia sebagaimana yang termaktub dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)
Alamat Tetap: 2539 - A KAMPUNG PAYA RESAK,
BUKIT PAYONG, 21400 KUALA
TERENGGANU, TERENGGANU. Tarikh: 23th June 2014
Disahkan oleh:
Cop Rasmi: Tarikh: 23th June 2014
** Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.
DECLARATION
I hereby, declared this report entitled “Machining Simulation of Composite
Materials Using Engineering Simulation Software” is the results of my own
research except as cited in references.
Signature :
Author’s Name : Zammeri Bin Abd Rahman
Date : 23th June 2014
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM
as a partial fulfillment of the requirements for the degree of Bachelor of
Manufacturing Engineering (Manufacturing Design) (Hons.). The member of the
supervisory is as follow:
………………………………
(Project Supervisor)
Proses pengisaran merupakan salah satu alat yang paling penting dalam proses
memotong bahan komposit dengan alat geometri operasi pengisaran yang kompleks.
Bahan komposit digunakan secara meluas dalam pelbagai sektor pembuatan
termasuk aeroangkasa, marin dan automotif. Terdapat kekurangan penyelidikan
tentang simulasi logam matriks komposit yang menggunakan Kaedah Unsur
Terhingga 3D (FEM) dalam proses pengisaran dan kaedah unsur terhingga 2D tidak
boleh mensimulasikan proses pengisaran yang kompleks. Oleh itu, kajian simulasi
bermaklumat dengan lebih realistik 3D Model Unsur Terhingga (FEMs) dan juga
model pemotongan ortogon untuk proses pengisaran yang kompleks CFRP/AL2024
telah dibangunkan untuk meramalkan mata alat dan bahan kerja menggunakan 3D
Analisis Unsur Terhingga (FEA) dengan menggunakan ABAQUS/EXPLICIT.
Akhirnya keputusan agihan tegasan, suhu pengisaran, daya pemotongan dan
pembentukan cip diperolehi. Model ini mengambil kira kesan yang dinamik, undang-
undang kerosakan bahan dan kriteria kenalan. Projek ini juga membangunkan Model
3D dalam pemesinan Realiti Maya (VR) yang memberikan satu penyelesaian yang
optimum penjanaan laluan mata alat dengan bantuan simulasi menggunakan
VERICUT. Simulasi dan pemodelan proses pemotongan mempunyai potensi untuk
mengoptimumkan parameter pemesinan dan meningkatkan reka bentuk alat
pemotong, terutamanya dalam pengisaran termaju yang berkelajuan tinggi.
ABSTRACT
i
The milling process is one of the most important tool for cutting process in milling
operation of composite material with the complex tool geometry. Composite
materials are widely used in a variety of manufacturing sectors including the
aerospace, marine and automotive industries. There is a lack of research on
simulating the metal matrix composites using 3D Finite Element Methods (FEM) in
the milling process and the 2D finite element methods cannot simulate the complex
milling process. Therefore, an informative simulation study with more realistic 3D
Finite Element Models (FEMs) as well as an orthogonal cutting model for the
complex milling process of CFRP/AL2024 was developed to predict tool and
workpiece using 3D Finite Element Analysis (FEA) with ABAQUS/EXPLICIT.
Finally the results of stress distribution, milling temperatures, cutting force and chip
formation are obtained. This model takes into account the dynamic effect, material
damage law and contact criteria. This project also develops the 3D Model in Virtual
Reality (VR) machining that to give an optimal solution of the tool path generation
with the help of simulation using the VERICUT. Simulation and modelling of cutting
processes have the potential for optimizing machining parameters and improving the
cutting tool design, especially in advanced high-speed milling.
ABSTRACT
ii
Special Dedication to my beloved parents and family,
My fellow colleague, My friends,
and all faculty members,
Who have support and guidance me.
Who is always there for me and always prays for me,
DEDICATION
iii
First and foremost, I would like to express my biggest appreciation to my respected
final year project supervisor, Engr. Dr. Mohamad Bin Minhat for all his precious
supports and advices during completing this project report. With his kindness, he
gives his best guidance and assistance throughout my final year project and
preparation of this report writing. I would like to lovely appreciate his willingness to
spend some time with me while doing this project.
My sincere appreciation also extends to all my fellow colleagues and people who
have involved directly and indirectly to give contribution and provided assistance at
various occasions. Their views and tips are useful indeed to complete my project
reports. Great appreciation also gives to my lectures who have taught me throughout
my study in Universiti Teknikal Malaysia Melaka. Also not forget, my special thanks
go to all staff in Faculty of Manufacturing Engineering UTeM. Last but not least, I
also would like to thanks to all my family members that give fully guidance and
moral support in completing this project.
Thank you.
ACKNOWLEDGEMENT
iv
Abstrak i
Abstract ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables viii
List of Figures ix
List Abbreviations, Symbols and Nomenclature xi
CHAPTER 1 : INTRODUCTION 1
1.1 Overview 1
1.2 Problem Statement 3
1.3 Objectives 4
1.4 Scope of Work 4
1.5 Chapters Organization 5
CHAPTER 2 : LITERATURE REVIEW 6
2.1 Background 6
2.2 Previous Research Work on Composite Machining 8
2.3 Composite Materials 10
2.3.1 Carbon Fiber Reinforced Plastic (CFRP) 11
2.3.2 Manufacture Process of CFRP 12
2.3.3 Aluminum Alloy (AL2024) 12
2.4 Machining Simulation Using Engineering Simulation Software 13
2.4.1 Machining Simulation 16
2.4.2 Engineering Simulation Software 16
2.4.3 Finite Element Simulation of Machining Process 17
2.4.4 Process Simulation Approach 18
2.4.5 Mesh Adaptivity 19
TABLE OF CONTENT
v
2.4.6 ABAQUS/CAE software 20
2.4.7 ABAQUS/EXPLICIT 21
2.4.8 VERICUT Simulation software 21
2.5 Chapter Summary 22
CHAPTER 3 : METHODOLOGY 23
3.1 Project Planning 23
3.2 Process Planning Using ABAQUS 26
3.3 Stages in ABAQUS/CAE Analysis 28
3.3.1 Pre-processing (ABAQUS/CAE) 28
3.3.2 Simulation (ABAQUS /EXPLICIT) 29
3.3.3 Post processing (ABAQUS /CAE) 29
3.4 Composites Modeler for ABAQUS Using SIMULAYT Add-On 30
3.4.1 Composite Modeler with SIMULAYT Composite Modeler 31
3.4.2 Methods to Create Composite Modeler with SIMULAYT 33
3.5 Finite Element Modelling (FEM) for CFRP/AL2024 34
3.5.1 3D Finite Element Modelling (FEM) 34
3.5.2 Orthogonal Finite Element Modelling (FEM) 35
3.5.3 Material Properties and Material Constitutive 36
3.5.4 Material Damage Criteria 38
3.5.5 Contact Model Analysis 38
3.6 Process Planning Using VERICUT 39
3.6.1 Development of the Simulation Environment in VERICUT 41
3.6.2 3D Model in SOLIDWORKS (Static Models) 41
3.6.3 Simulation of Tool Path Using VERICUT 42
3.7 Chapter Summary 43
CHAPTER 4 : RESULT & DISCUSSION 44
4.1 Data Grouping 44
4.2 Design and Modelling of Parts 45
4.3 Defining the Material’s Properties in ABAQUS 49
4.4 Composites Modeler Draping Simulations and Solid Extrusion 50
4.5 Assembly Meshing in ABAQUS 54
vi
4.6 Process of Simulation in 3D Finite Element Modelling (FEMs) 55
4.7 XY Data Graph 62
4.8 Construction Of The Virtual Machine in VERICUT 63
4.9 Design and Modeling The Machine 64
4.10 Process Simulation of Tool Path in VERICUT 66
4.11 Chapter Summary 68
CHAPTER 5 : CONCLUSION & FUTURE WORK 69
5.1 Conclusions 69
5.2 Recommendations for Future Work. 71
3.3 Chapter Summary 72
REFERENCES 73
APPENDICES
A Gantt Chart of PSM
B Analysis Input File Reported
C Field Output Reported At Integration Points
D Processing Part, Instance, And Assembly Information Ouput
vii
3.1 Arrangement of the laminates 36
3.2 Physical Properties of CFRP 37
3.3 Constant parameters for the Johnson–Cook material model of CFRP 37
3.4 Fracture parameter for CFRP, Al2024 and PCD 38
3.5 End mill cutting condition under the milling process 42
LIST OF TABLES
viii
1.0 Scope of works (SOW) 4
2.1 Auto-clave molding (CFRP) 12
2.2 Optional simulation software tools 17
2.3 Lagrangian process model with damage/element deletion 18
2.4 Eulerian (ALE) process model/example results 19
2.5 Meshing 3D model for the simulation of machining 20
2.6 Schematic diagram of tool path and machining operation 22
3.1 Project plan flow chart 25
3.2 Process plan flow chart using ABAQUS 27
3.3 Stages in ABAQUS/CAE analysis 28
3.4 The solid model of CFRP/AL2024 layup using SIMULAYT
Composites Modeler for ABAQUS/CAE (CMA) V2013
30
3.5 The procedure to create composite modeler with SIMULAYT
Plug-in Version 2013
31
3.6 Methods to create composite modeler with SIMULAYT 33
3.7 3D Finite Element Model (FEM) for milling of CFRP/AL2024 34
3.8 Meshing elements of workpiece material for CFRP/AL2024 and
tool geometry
36
3.9 Process plan flow chart using VERICUT 40
3.10 Framework of simulation for virtual milling process 41
3.11 Virtual environment designed for milling process of the
3- Axis FANUC CNC vertical milling machine
43
4.1 Flat bottom end mill model designed using CATIA V5.21 45
4.2 Flat bottom end mill model import from CATIA V5.21 to
ABAQUS/CAE V6.13
46
LIST OF FIGURES
ix
4.3 Flat bottom end mill solid model with element type in
ABAQUS/CAE V6.13
46
4.4 Associative import to export a model from CATIA V5 to
ABAQUS/CAE
47
4.5 Assembly modelling of 3D FEM using ABAQUS V6.13 48
4.6 Assembly modelling of orthogonal cutting using ABAQUS V6.13 48
4.7 Material defining for the composite layup of CFRP/AL2024 49
4.8 Solid mesh of CFRP/AL2024 layup using SIMULAYT composites
modeler for ABAQUS/CAE (CMA) V2013
50
4.9 Condition of layup laminate materials in materials dialog box. 51
4.10 CSYS coordinate system direction with Strain Plies of
CFRP/AL2024
52
4.11 The layup of seven plies using CFRP and AL2024 material with
different number of ply and angle offset
53
4.12 The cloning a ply with layup model of CFRP/AL2024 53
4.13 Assembly meshing of the workpiece and cutting tool in 3D FEM
process
54
4.14 Assembly meshing of the workpiece and cutting tool in orthogonal
cutting process
55
4.15 The stress distribution of 3D FEM at different cutting times
(A, B, C, D, E and F)
57
4.16 The stress distribution of orthogonal cutting chip formation at
different cutting times (A, B, C, D, E and F)
59
4.17 The temperature distribution of orthogonal cutting chip formation at
different cutting times (A, B, C, and D)
60
4.18 Discontinuous and Continuous Chip for Orthogonal Cutting 61
4.19 XY graph between the milling Forces (N) versus Time (s) 63
4.20 3D wire frame model from SOLIDWORKS Premium 2012 64
4.21 3D model of 3-Axis FANUC vertical milling machine in VERICUT
V7.1.6
65
4.22 The result of simulation tool paths in VERICUT 66
4.23 Optimized G & M Codes in CNC program as a text format 67
x
AL2024 - Aluminum
Al2O3 - Alumina
Ti6A14V - Titanium alloy
ALE - Arbitrary Lagrangian Eulerian
ASTM - American Society for Testing and Materials Standards
BC's - Boundary Conditions
CAD - Computer Aided Drafting
CAE - Computer Aided Engineering
CAM - Computer Aided Machining
CBN - Cubic Boron Nitride
CDM - Continuum Damage Modelling
CFRP - Carbon Fiber Reinforcement Polymer
CM - Composite Modeler
CMA - Composite Modeler for ABAQUS
CNC - Computer Numerical Control
DoE - Design of Experiments
DoF - Degree of Freedom
FE - Finite Element
FEA - Finite Element Analysis
FEM - Finite Element Method
FEMs - Finite Element Models
FRP - Fibre Reinforced Plastics
FYP - Final Year Project
GFRP - Glass Fibre Reinforced Plastics
HSM - High Speed Machining
NC - Numerical Control
PCD - Polycrystalline Coated Diamond
PSM - Projek Sarjana Muda
LIST OF ABBREVIATION, SYMBOLS AND
NOMENCLATURE
xi
R&D - Research And Development
RSM - Response Surface Model
SFTC - Scientific Forming Technologies Company
SOW - Scope of Works
SHPB - Split Hopkinson Pressure Bar
VR - Virtual Reality
exp - Exponential
D - Diameter
F - Feed Rate
Gpa - Giga Pascal
Kg - Kilogram
L - Length
m - Melting
min - Minute
mm - Millimetre
Mpa - Mega Pascal
N - Value of cutter
P - Parameters
Q - Misses Stress
Ra - Surface roughness
rpm - Revolution per minute
s - Second
T - Temperature
Tm - Melting Temperature
Tr - Room Temperature
V - Cutting Speed
W - Weight
Z - Number of teeth
xii
This chapter contains the introduction and project background. This project is carried
out based on the simulation and analysis of the milling process of carbon fibre
composites CFRP/Al2024. Problem statements, objectives and scopes of this project
are also discussed. There is also a chapter organization that explains about the overall
subject in this report.
1.1 Overview
Composite is a superior material that is preferred in aerospace, marine and
automotive industries. It is made up of a matrix material completely surrounding the
reinforcement material to form unique properties and characteristics which do not
exist in the matrix material naturally (R. Rusinek, et al., 2011). When the two phases
unite to form a composite, it has properties or features that are not available in the
original constituents of the composite materials formed (Alwarsamy et al., 2012).
Recently, composite became the most preferred material in the aerospace industry
due to the many benefits it provides, such as superior strength to weight ratio,
stiffness, good fatigue as well as corrosion resistance and low manufacturing cost
(NorKhairusshima M.K et al., 2011). Despite its excellent characteristics, machining
of composite is difficult to conduct due to its high abrasiveness, non-homogenous
and anisotropic structure (Klinkova et al., 2011). Research of composite machining
mostly concentrates on drilling and turning. Rahman et al., (1999) developed feasible
techniques for turning on Carbon Fibre Reinforced Plastics (CFRP).
INTRODUCTION
CHAPTER 1
1
According to Ferreira et al., (1999) focused on tool wear and illustrated the
performance of different tool materials and supports that only Polycrystalline Coated
Diamond (PCD) tool are suitable for used in finish turning. Palanikumar et al.,
(2004) presented an investigation on optimization of machining parameters for
surface roughness using Design of Experiments (DoE) on different types of Glass
Fibre Reinforced Plastics (GFRP). Hariharan et al., (2012) the influence of tool wear
in a drilling process of CFRP composites is very high. Phadnis et al., (2012)
developed 3D Finite Element Model (FEM) of drilling CFRP/A2024. However, there
are few researchers dealing with machining of composite material using a CNC
milling machine (NorKhairusshima M.K et al., 2011, Alwarsamy et al., 2012). To
improve the manufacturing quality, performance of the tool, optimum cutting
conditions and cost reduction are the key area need to be considered. On the other
hand, the academicians are continually looking for alternatives that help of a better
understanding of the metal cutting process.
Generally, there are two most common methods of conducting experiments
associated with the machining process. First is by preparing some sample, set-up on
the machine with predefined machining parameters and finally some data will be
collected depending on the purpose of the experiments. However, this method has
proved to be more expensive, especially dealing with composite materials. The
second method is called simulation. Simulation models are very important in the
machining process as comprehension and for the reduction of experimental tests.
Results obtained from the simulation provides better understanding of system
behaviour and in turn help in the process of optimization of tool geometries, cutting
conditions and other parameters like the choice of the tool material and coating.
Simulation eventually enables good predictions in the cutting force, stress and strain
distribution. This will contribute to cost reductions for the machining process
optimization that are still experimentally done and thus expensive (Madalina C. et
al., 2008). Therefore, there are few researchers are focusing on modelling and
simulation techniques to predict and optimize certain machining parameters such as
the cutting force, surface roughness, stress–strain analysis etcetera. These techniques
do not need to perform many experimental tests that will cost a lot of money and are
time consuming (Hamed S. et al., 2007).
2
1.2 Problem Statement
CFRPs are an expensive material that fast gaining ground as the preferred material to
replace the traditional material used for construction of aircraft and spacecraft (W. N.
F. Mohamad et al., 2013). In recent years, the combinations of CFRP/metals to form
a composite material have also gained popularity (Klinkova et al., 2011; R. Rusinek,
et al., 2011). Literature reviews relevant to the field of composite material machining
most often focus on analysis of cutting tools wear and methods of optimization for
surface roughness. Most of the research conducted by performing actual machining
operation which actually very expensive and time consuming. Another method of
experiment which is less costly as described previously is simulation. Generally,
most of the machining simulation only provides limited information such as tool path
generations and errors/collision detection, Output like surface roughness, tool wear,
cutting forces etcetera are not readily available on request.
Therefore, in this project, the simulation of the machining process of CFRP/AL2024
is conducted using the engineering simulation software. However, complex milling
process cannot be simulated by 2D finite element methods (H. B. Wu. S. J. Zhang,
2013). Therefore, an informative simulation study with more realistic 3D Finite
Element Model (FEM) and orthogonal cutting model for the complex milling process
of CFRP/AL2024 is developed. This model takes into account the dynamic effect,
material damage law and contact criteria. Also the 3D Model developed in virtual
machining would give an optimal solution of the tool path generation with the help
of simulation. Simulation and modelling of cutting processes have the potential for
optimizing machining parameters and improving the cutting tool designs, especially
in advanced high-speed milling.
3
1.3 Objectives
The overall aim of the Final Year Project (FYP) is to study and develop a
methodology for simulating the machining process of CFRP/Al 2024 using a milling
machine. The aim can be resolved into the following specific objectives:-
• To develop 3D Finite Element Model (FEM) for milling process using 3D
Finite Element Analysis (FEA) with ABAQUS/EXPLICIT software.
• To simulate machining tool path, under the selected cutting conditions
(speed, feed rate and depth of cut) using the VERICUT software.
1.4 Scope of Work
3D Finite Element Models
(FEMs)
Orthogonal Cutting
Milling Process
Simulation Tool Path
Actual Machining
Simulation/Analysis Using Engineering
Simulation Software
Not M
eant
CFRP/AL2024 Materials
Figure 1.0: Scope of works (SOW)
Figure 1.0 shows the Scope of Works (SOW) in this Final Year Project (FYP). The
scopes of the project are mainly focused on studying about analysis and simulation in
the milling process of CFRP/Al2024. In this project, an informative simulation study
with a more realistic 3D Finite Element Models (FEMs) as well as an orthogonal
cutting model has been developed to simulate the complex milling process of
CFRP/AL2024 using the engineering simulation software.
4
This project also develops the 3D Model in virtual reality machining that to give an
optimal solution of the tool path generation with considering speed, feed rates, and
depth of cut with the help of simulation. The data from the observation and
compilation will be used in simulation, applications of machining for verification. It
will then help to analyze more conditions affecting the machinability of
CFRP/AL2024. These studies are not meant for actual machining.
1.5 Chapters Organization
This dissertation consists of five chapters which is covered on PSM 1 and PSM 2.
The report includes of introduction, literature review, methodology, result and
conclusion. The first chapter introduces the background of the project, problem
statement, objectives, scopes of the project and the report structure for overview the
whole chapters in the report. Then follow by literature review on Chapter 2 which
more on the research about the related project and review on the previous research
work in composite machining, machining simulation and analysis using engineering
simulation software. Chapter 3 focuses on the project planning as well as the
methodology used during completing this project to ensure this project is
successfully completed on the specified time period. This chapter explains about the
flow of process planning, equipment and software application will be conducted.
Chapter 4 describes the result and discussion of this project from the simulation and
analysis process that has traversed. This project report ends with the conclusion of
Chapter 5. Conclusions are made based on the result of simulation and analysis that
have been conducted. Finally, suggestion and recommendation for the future work
also included in this final chapter to improve this project.
5
The purpose of this chapter is to provide a general overview of past and current
research work and placing the FYP project in wider context of simulation. All
relevant information related to this project is refined and structurally present in
this chapter. This literature review is vital to help in generating ideas to complete
the tasks and project. The section of this report will review on previous research
work on composite machining, composite materials, and machining simulation
using engineering simulation software. Towards the end of this chapter, a
summary of the literature is presented.
2.1 Background
Machining operations of composite materials which especially carbon fibre is
extensively used in the aerospace industry in order to create smoothness on the
desired surface and make a prototype part from a big blank or set of materials.
Machining of the materials is very common and easily performed (Klinkova et al.,
2011; R. Rusinek et al., 2011). However, the machining of the composite has proved
to be more challenging. Machining of the composite material parts generates
discontinuity in the fibre and thus affect the performance of the part, the temperature
during the cutting process must be considered where it should not exceed the cure
temperature or close to the melting temperature of the resin to avoid material
disintegration. During machining process the smaller values of feed rate are much
better as far as the tool life is concerned (W. N. F. Mohamad et al., 2013; Alwarsamy
et al., 2012).
LITERATURE REVIEW
CHAPTER2
6
Adversely, this causes the process consuming more time and are very expensive.
Machining also exposed the fibre to chemical and moisture and the effect of coolant
materials on composites. The machining of composite materials required for dry
machining process without using any coolant, or cutting fluid (W. N. F. Mohamad et
al., 2013). This is due to the composite materials will expand if using the coolant or
any cutting fluid during machining. The mechanical damage will occur faster when
the workpiece that manufactured with composites are exposed to moisture and
elevated temperature. The presence of water modifies the properties of the matrix
and affected the mechanical properties such as strength, stiffness and creep (Rahman
et al., 1999). Furthermore, there are several advantages by using dry cutting it will
reduce the cost of machining (Premnath et al., 2012).
In the field of cutting process research, the Finite Element Method (FEM) is regarded
as a ve1y useful tool to study the cutting process of materials. Many finite element
models have been developed, including orthogonal cutting model, oblique cutting
model, and 3D FEM. The orthogonal FEM has been more used to investigate the
cutting mechanism. Simoneau et al., (2006) studied chip formation of medium
carbon steel using 1hc orthogonal cutting model. Jin and Altintas, (2012) predicted
micro-milling forces with the orthogonal model.
According to Mohammadpour et al., (2010) investigated the effect of machining
parameters on residual stresses in orthogonal cutting. Molinari et al., (2011) studied
the link between local variables and global contact characteristics in orthogonal
cutting using the finite element method. Shams and Mashayekhi, (2012) established a
nonlocal damage model to improve the orthogonal cutting simulation. Deng et al.,
(2009) used an orthogonal FEM to investigate burr formation. Zhang et al., (2012)
investigated the cutting process of Ti6A14V based on crystal plasticity theory and
discrete cohesive elements. Afazov et al., (2010) predicted micro-milling, cutting
forces through the orthogonal cutting FEM.
7
