Abstract
The machining of cellular metals has been a challenge, as the resulting surface is extremely irregular, with torn off or smeared material, poor accuracy, and subsurface damage. Although cutting experiments have been carried out on cellular materials to study the influence of cutting parameters, current analytical and experimental techniques are not suitable for the analysis of heterogeneous materials. On the other hand, the finite element (FE) method has been proven a useful resource in the analysis of heterogeneous materials, such as cellular materials, metal foams, and composites. In this study, a two-dimensional finite element model of peripheral milling for cellular metals is presented. The model considers the kinematics of peripheral milling, depicting the advance of the tool into the workpiece and the interaction between the cutting edge and the mesostructure. The model is able to simulate chip separation as well as the surface and subsurface damage on the machined surface. Although the calculated average cutting force is not accurate, the model provides a reasonable estimation of maximum cutting force. The influences of mesostructure on cutting processes are highlighted and the effects in peripheral milling of cellular materials are discussed.
Highlights
Cellular metals are a relatively young material group with a heterogeneous structure formed by a three-dimensional metallic matrix with empty pores occupying over 70% of their volume [1]
A 2D mesoscopic finite element (FE) model to analyze the peripheral milling of cellular metals is presented
The model included the kinematics of peripheral milling, depicting the movement of the tool—into the workpiece and contact interaction between the cutting edge and the mesostructure
Summary
Cellular metals are a relatively young material group with a heterogeneous structure formed by a three-dimensional metallic matrix with empty pores occupying over 70% of their volume [1]. Some components could be prepared in near-net-shapes, but still some machining operations are common. Their field of application ranges from the chemical industry (heat exchanger, surface burner [2]) to lightweight applications with required high energy absorption capabilities [3]. Because conventional machining leads to a low surface quality and poor precision, electro-discharge machining (EDM) [4], chemical milling, or water-jet cutting are preferred for finishing [5]. It would be desirable to substitute them by conventional machining in order to increase productivity, it is necessary to reduce or eliminate the undesired surface defects caused by metal cutting. Previous peripheral milling tests performed for sintered cellular titanium [6] and open-cell cellular stainless steel [7]
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