Finite element analysis of orthogonal cutting of cellular metals: influence of cutting conditions on chip formation and surface damage

摘要: Cellular metals are highly porous materials with very distinctive properties. Although it is possible to manufacture near-net-shape parts of these some manufacturing processes, additional machining operations usually required. However, as conventional causes surface damage and poor precision, finishing often performed using alternative, cost-intensive methods. In the present work, a mesoscopic finite element model was used analyze influence cutting conditions tool geometry in orthogonal process cellular metals. The study considered variability mesostructure, behavior multiple cell arrangements under evaluated. speed, depth cut, rake angle on chip formation explored. Chip at higher speed different, fragmentation visible. Tools positive led decrease subsurface damage. Nevertheless, quality markedly dependent stochastic nature material separation defined by response array. Hence, set parameters for optimal could not be identified.