Eventos Anais de eventos
COBEF 2023
12th Brazilian Congress on Manufacturing Engineering
Review on FEM numerical simulation of micromachining processes
Submission Author:
Gabriel de Paiva Silva , GO
Co-Authors:
Gabriel de Paiva Silva, Lucival Malcher, Déborah de Oliveira
Presenter: Gabriel de Paiva Silva
doi://10.26678/ABCM.COBEF2023.COF23-0077
Abstract
In micromachining processes, the microtool cannot be assumed as perfectly sharp, in opposition to traditional machining in macro scale. This phenomenon happens because the cutting-edge radius of the microtool has the same size scale as the minimum chip thickness or even the microstructure of the workpiece material. This problem is known as size effect and it is detrimental for the understanding of the cut in micro scale. It is desirable for the industry to optimize the micromachining process by predicting output variables and possible problems caused by the size effect, in order to reduce costs. By knowing the mechanical properties of the workpiece, it is possible to use the Finite Element Method (FEM) to determine different output parameters. Thus, this article proposes a literature overview about the use of numerical simulations in micromachining processes. The following output parameters in micromachining were analyzed: chip formation and minimum chip thickness; cutting temperature; cutting forces; and burr formation. In most of the studies chosen for the present review, the Johnson-Cook plasticity model was used to characterize the mechanical behavior of the workpiece material since it has proved to be consistent with experimental data for some materials. It was possible to observe that the minimum uncut chip thickness is an important parameter in micromilling that is not yet completely predictable or understood, because it depends on several non-linearities that cannot always be taken into account in numerical simulations. On the other hand, the measurement of cutting forces tend to match experimental data more often. None of the analyzed studies focused in simulating the effect of cutting fluid application in micromachining, although the lubrication condition plays crucial role in determining the surface quality of micromachined surfaces. Finally, in the studies analyzed, it was possible to observe that microtool wear is not usually predicted through FEM, since tools are generally modelled as rigid bodies in numerical simulations. In general, according to the present review work, there are still many challenges in predicting output parameters in micromachining because there are several non-linearities that are aggravated by size effect.
Keywords
Michomachining, Finite Element Method, Numerical simulation
