FEM and Analytical Modeling of the Incipient Chip Formation for the Generation of Micro-Features
This paper explores the modeling of incipient cutting by Abaqus, LS-Dyna, and Ansys Finite Element Methods (FEMs), by comparing also experimentally the results on different material classes, including common aluminum and steel alloys and an acetal polymer. The target application is the sustainable m...
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doaj-c6148822c787484a8d43b4651b2fc3702021-07-23T13:51:16ZengMDPI AGMaterials1996-19442021-07-01143789378910.3390/ma14143789FEM and Analytical Modeling of the Incipient Chip Formation for the Generation of Micro-FeaturesMichele Lanzetta0Armin Gharibi1Marco Picchi Scardaoni2Claudia Vivaldi3Research Center “E. Piaggio”, School of Engineering, University of Pisa, 56126 Pisa, ItalyDepartment of Civil and Industrial Engineering, University of Pisa, 56126 Pisa, ItalyDepartment of Civil and Industrial Engineering, University of Pisa, 56126 Pisa, ItalyDepartment of Civil and Industrial Engineering, University of Pisa, 56126 Pisa, ItalyThis paper explores the modeling of incipient cutting by Abaqus, LS-Dyna, and Ansys Finite Element Methods (FEMs), by comparing also experimentally the results on different material classes, including common aluminum and steel alloys and an acetal polymer. The target application is the sustainable manufacturing of gecko adhesives by micromachining a durable mold for injection molding. The challenges posed by the mold shape include undercuts and sharp tips, which can be machined by a special diamond blade, which enters the material, forms a chip, and exits. An analytical model to predict the shape of the incipient chip and of the formed grove as a function of the material properties and of the cutting parameters is provided. The main scientific merit of the current work is to approach theoretically, numerically, and experimentally the very early phase of the cutting tool penetration for new sustainable machining and micro-machining processes.https://www.mdpi.com/1996-1944/14/14/3789micromachiningchip formationfinite element methodadhesionsustainability |
collection |
DOAJ |
language |
English |
format |
Article |
sources |
DOAJ |
author |
Michele Lanzetta Armin Gharibi Marco Picchi Scardaoni Claudia Vivaldi |
spellingShingle |
Michele Lanzetta Armin Gharibi Marco Picchi Scardaoni Claudia Vivaldi FEM and Analytical Modeling of the Incipient Chip Formation for the Generation of Micro-Features Materials micromachining chip formation finite element method adhesion sustainability |
author_facet |
Michele Lanzetta Armin Gharibi Marco Picchi Scardaoni Claudia Vivaldi |
author_sort |
Michele Lanzetta |
title |
FEM and Analytical Modeling of the Incipient Chip Formation for the Generation of Micro-Features |
title_short |
FEM and Analytical Modeling of the Incipient Chip Formation for the Generation of Micro-Features |
title_full |
FEM and Analytical Modeling of the Incipient Chip Formation for the Generation of Micro-Features |
title_fullStr |
FEM and Analytical Modeling of the Incipient Chip Formation for the Generation of Micro-Features |
title_full_unstemmed |
FEM and Analytical Modeling of the Incipient Chip Formation for the Generation of Micro-Features |
title_sort |
fem and analytical modeling of the incipient chip formation for the generation of micro-features |
publisher |
MDPI AG |
series |
Materials |
issn |
1996-1944 |
publishDate |
2021-07-01 |
description |
This paper explores the modeling of incipient cutting by Abaqus, LS-Dyna, and Ansys Finite Element Methods (FEMs), by comparing also experimentally the results on different material classes, including common aluminum and steel alloys and an acetal polymer. The target application is the sustainable manufacturing of gecko adhesives by micromachining a durable mold for injection molding. The challenges posed by the mold shape include undercuts and sharp tips, which can be machined by a special diamond blade, which enters the material, forms a chip, and exits. An analytical model to predict the shape of the incipient chip and of the formed grove as a function of the material properties and of the cutting parameters is provided. The main scientific merit of the current work is to approach theoretically, numerically, and experimentally the very early phase of the cutting tool penetration for new sustainable machining and micro-machining processes. |
topic |
micromachining chip formation finite element method adhesion sustainability |
url |
https://www.mdpi.com/1996-1944/14/14/3789 |
work_keys_str_mv |
AT michelelanzetta femandanalyticalmodelingoftheincipientchipformationforthegenerationofmicrofeatures AT armingharibi femandanalyticalmodelingoftheincipientchipformationforthegenerationofmicrofeatures AT marcopicchiscardaoni femandanalyticalmodelingoftheincipientchipformationforthegenerationofmicrofeatures AT claudiavivaldi femandanalyticalmodelingoftheincipientchipformationforthegenerationofmicrofeatures |
_version_ |
1721287394403024896 |