[en] This paper presents a comprehensive review of the concept of machinability by considering the dynamic, tribological, and thermo-mechanical interactions encountered at the tool-chip-machined surface interfaces. The paper provides a demonstration of the capabilities and gaps of the physics-based models for the characterization of the machining performance and the prediction of machinability of difficult-to-cut materials, including additively manufactured (AM) materials, nanocrystalline (NC) materials, fibre reinforced polymers (FRP), metal matrix composites reinforced with ceramic hard particles (MMC), and ceramic matrix composites (CMC). The utilization of efficient computation methods for accurate prediction of force, torque, power consumption, cutting temperature, deflection errors, vibration amplitudes, chatter stability, and thermomechanical interactions in the tool-workpiece system is discussed. The development of thermally-activated dissolution-diffusion wear models to describe the chemical reactions at the tool-chip-workpiece contact interfaces is also presented. These predictions are critical for identifying multi-objectives optimal machining conditions. The integration of predictive machining models within the framework of digital twins in cyber-physical spaces, for in-process monitoring and adaptive control, is demonstrated. Future research for developing new models that can characterize the machinability of AM and NC materials, by considering the effects of varying material microstructure and anisotropy, is presented for conventional and micro-machining operations.
Disciplines :
Mechanical engineering
Author, co-author :
Attia, H.; Mechanical Engineering Department, McGill University, Montreal, Canada ; Aerospace Manufacturing Technology Centre, National Research Council Canada, Canada
Sadek, A.; Aerospace Manufacturing Technology Centre, National Research Council Canada, Canada
Altintas, Y.; Department of Mechanical Engineering, University of British Columbia, Vancouver, Canada
Matsubara, A.; Department of Micro Engineering, Kyoto University, Kyoto, Japan
Umbrello, D.; Department of Mechanical, Energy and Management Engineering, University of Calabria, Arcavacata, Italy
Wegener, K.; Department of Mechanical and Process Engineering,.IWF-ETH Zürich, Switzerland
Eisseler, R.; Institute for Machine Tools, University of Stuttgart, Germany
Ducobu, François ; Université de Mons - UMONS > Faculté Polytechnique > Service de Génie Mécanique
Ghadbeigi, H.; Department of Mechanical Engineering, University of Sheffield, Sheffield, United Kingdom
Language :
English
Title :
Physics based models for characterization of machining performance – A critical review
Publication date :
July 2024
Journal title :
CIRP Journal of Manufacturing Science and Technology
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