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Simulation of Chip Segmentation in Metal Cutting Using ALE Finite Element Method
, M.Sc. Thesis Sharif University of Technology ; Movahhedy, Mohammad Reza (Supervisor)
Abstract
Since it is important to obtain the suitable cutting conditions for machining and investigate the effect of various parameters on this process, the simulation of this process has been developed extensively by using the finite element method in recent years. Due to very large plastic deformation and also continuous chip flow, one of the most appropriate techniques in modeling chip formation is the arbitrary Lagrangian-Eulerian (ALE) finite element method which has been used in several papers using some traditional codes like ABAQUS or personal codes in recent years. However, one of the limitations in this method is the use of a continuous mesh retains with no change in connectivities which is...
DMLS gets an expert once-over
, Article Metal Powder Report ; Volume 61, Issue 4 , 2006 , Pages 10-13 ; 00260657 (ISSN) ; Pohl, H ; Simchi, A ; Alcantara, B ; Sharif University of Technology
Elsevier Ltd
2006
Abstract
Direct Metal Laser Sintering has real potential for rapid-manufacture applications in the PM arena, reducing lead times and cutting costs. But it has been hampered by the limited range of suitable powders available and their cost. A research group led by Fraunhofer scientists made their own powders and took a closer look.... © 2006 Elsevier Ltd. All rights reserved
Investigation of cutting model in machining of Al/SiC p metal matrix composite
, Article Applied Mechanics and Materials, 18 November 2011 through 20 November 2011, Shenzhen ; Volume 117-119 , 2012 , Pages 1465-1470 ; 16609336 (ISSN) ; 9783037852804 (ISBN) ; Kouchakzadeh, M. A ; Yousefi, R ; Kadivar, M. A ; Sharif University of Technology
2012
Abstract
Prediction of shear plane angle is a way for prediction of the mechanism of chip formation, machining forces and so on. In this study, Merchant and Lee-Shaffer theories are used to predict the shear plane angles and cutting forces in machining of Al/SiC p MMC. The experimental cutting forces are compared with the calculated cutting force based on shear plane angles extracted from Merchant and Lee-Shaffer theories. The variation of these cutting forces with cutting speed, feed rate and depth of cut has been discussed. The results show that Merchant theory may be used as a good method for prediction of chip formation in machining of Al/SiC p MMC
Cutting model in machining of Al/SiC p metal matrix composite
, Article Advanced Materials Research, 15 December 2011 through 18 December 2011, Hong Kong ; Volume 410 , 2012 , Pages 291-297 ; 10226680 (ISSN) ; 9783037853160 (ISBN) ; Yousefi, R ; Kouchakzadeh, M. A ; Kadivar, M. A ; Sharif University of Technology
2012
Abstract
Prediction of shear plane angle is a way for prediction of the mechanism of chip formation, machining forces and so on. In this study, Merchant and Lee-Shaffer theories are used for prediction of shear plane angles and cutting forces in machining of Al/SiC p MMC with 20% of SiC as reinforcement particles. The experimental cutting forces are compared with the calculated cutting force based on shear plane angles extracted from Merchant and Lee-Shaffer theories. The variation of these cutting forces with cutting speed, feed rate and depth of cut has been discussed. The results showed that Merchant theory may be used as a good method for prediction of chip formation in machining of Al/SiC p MMC
Investigating the effects of vibration method on ultrasonic-assisted drilling of Al/SiCp metal matrix composites
, Article Robotics and Computer-Integrated Manufacturing ; Vol. 30, issue. 3 , 2014 , Pages 344-350 ; ISSN: 07365845 ; Akbari, J ; Yousefi, R ; Rahi, A ; Nick, M. G ; Sharif University of Technology
Abstract
Preciseness and finished surface quality are the significant factors of final products, especially in a number of drilling processes. Burr is usually considered a negative outcome in assembly procedures. One way to reduce or remove burr and improve surface roughness in metal cutting is to employ ultrasonic vibration in the drilling process. In this paper, the effects of ultrasonic vibration on burr size reduction, drilling force and surface roughness with two different vibration systems are investigated. To this end, two vibration structures were built, one to excite the workpiece (the workpiece vibration system) and the other to vibrate the tool (the tool vibration system). Besides, the...
Investigation of thermal effects on machining chatter based on FEM simulation of chip formation
, Article CIRP Journal of Manufacturing Science and Technology ; Vol. 7, issue. 1 , 2014 , p. 1-10 ; Movahhedy, M. R ; Moradi, H ; Sharif University of Technology
Abstract
In this paper, thermo mechanical finite element analysis of orthogonal machining process with a flexible tool is carried out to study the dynamic behaviour of the machining system and its stability against chatter vibration. By combining the simulation of chip formation in metal cutting with the dynamic phenomena leading to chatter development, the influence of various phenomena, including thermal effects resulting from friction and plastic deformations on the stability of the process are investigated. The novelty of this model is in its ability to evaluate the effect of temperature rise in the cutting zone on the stability of cutting process. Process stability is analyzed and compared for...