CCAT National Aerospace Leadership SubcontractCCAT国家航天领导分包.ppt

Physics-Based Process Modeling offering cost reduction, time saving, and engineering decision assistance for machining and other processes December 8th, 2005 Overview Objective of process simulation Classification of different machining models Overview of Process Modeling Physic-Based Models Mechanistic Models Finite Element Models Why Process Modeling Process Simulation provides fundamental understanding of the relationships between process variables: Optimal range of cutting parameters Chip morphology and cutting forces Development of temperatures and stresses Influence of tool wear and premature tool failure Dynamics of the tool/workpiece/machine system Workpiece surface integrity and residual stress Process simulation reduce number of iterations and results in a substantial cost savings Classification of different machining models Process Modeling Physic-Based ModelsTo developed Finite Element and/or Mechanistic models to investigate specific aspects of manufacturing process Physics-Based Model - Concept of Mechanistic ModelsMechanistic-based modeling enables optimization of all machining process 3. Friction characteristics in the interface zone Friction occurs at the chip tool interface under extreme conditions of temperature, pressure, and strain. It is important to determine the coefficient of friction experimentally since it is dependent on cutting conditions and tool geometry. Friction conditions affect the chip formation and consequently the accuracy of the results obtained Tremendous amount of machining data can be obtained from each run, the following results are of general interest: Predicted Residual Stress Predicted Cutting Forces Predicted Temperature Predicted Stresses on tool face Definition of Residual Stresses in Metal Cutting Residual stress is defined as the stress that exists in an elastic body after all the external loads are removed. Residual stress classification Residual stress is classified into two different types depending