Thermomechanical analysis of machining and brazing
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1 Research Collection Doctoral Thesis Thermomechanical analysis of machining and brazing Author(s): Akbari, Mansur Publication Date: 2016 Permanent Link: This page was generated automatically upon download from the ETH Zurich Research Collection. For more information please consult the Terms of use. ETH Library
2 DISS. ETH NO Thermomechanical analysis of machining and brazing A thesis submitted to attain the degree of DOCTOR OF SCIENCES of ETH ZURICH (Dr. sc. ETH Zurich) presented by Mansur Akbari M.Sc. University of Tehran, faculty of engineering born on 11th September 1978 citizen of Iran accepted on the recommendation of Prof. Dr. Konrad Wegener, examiner Prof. Dr. Pavel Hora, co-examiner 2016
3 Abstract Abstract A deep understanding of the physics of machining processes helps driving the further development of new processes and cutting tools. The present work comprises the development and provision of simulation tools for an understanding and methodological improvement of machining processes. This is conducted under consideration of pre-damaging of tools due to their manufacturing, which until today has not been sufficiently addressed in research and development. Furthermore, this work provides an insight into the process-induced loads on the tool and their dependency on its geometry, through a thermomechanical simulation of the machining process with defined and non-defined cutting edges. For all simulation approaches, the material and system data must be identified and estimated. This is particularly challenging for the simulation of machining processes, as no standardized experimental procedures exist for parameter identification. Therefore, inverse material modelling was applied for determining material and system data. The required simulation tools are derived in the present work. Grinding for instance is one of the most complex machining processes, whose modelling is limited by the stochastic nature of the single grain interaction. Thermomechanical analysis of the interaction between grain and workpiece material leads to a better understanding of the complex grinding process. The cutting edge radii of tools significantly influence the machining process and tool wear, which also applies to individual grains. Hence, the analysis of the cutting edge radii of diamond grains is an essential prerequisite for modelling. Therefore, this work presents and compares a number of methods to measure cutting edge radii on diamonds.. Important aspects in the simulation of machining processes are the thermal influences on the tool and workpiece. A realistic simulation of the process has to consider also the thermomechanical coupling. Additionally, the large plastic deformations require consideration of material damage within the constitutive laws of the workpiece material. Another challenge in the simulation of the chip formation in the grinding process is the large negative rake angle of the single grain and small depth of cut, necessitating an extremely fine discretization in the numerical method. The combination of numerical methods with experimental evaluations provides a more detailed insight into the grinding process than experiments or numerical methods alone. To tackle the challenges in three-dimensional analysis of XIV
4 Abstract machining processes, the finite element method with updated Lagrangian algorithms, implicit time integration, methods for local remeshing and a damage model according to Johnson-Cook (JC) are used. It is found that in cutting with large negative rake angle, the cutting and passive forces are reduced with decreasing cutting edge radii. A Johnson-Cook damage limit value of 0.7 leads to the best correlation between the three components of the cutting forces obtained from single diamond scratch testing and simulation. Through variation of cutting edge radii, the influence of wear can be approximated. However, the experimental measurement of cutting edges presents a challenge in itself, due to the transparency, reflectivity and abrasiveness of the diamond grains, which hinder optical as well as contact measurement methods. The method of Wyen can be applied to use radii from the obtained raw data for the characterization of the cutting edge. In this work, a number of measurement methods are tested and compared, such as tactile profilometry, confocal and focus variation light microscopy, imprinting, scanning electron microscope (SEM) stereoscopy, and atomic force microscopy (AFM). Based on these measurements, a framework for the selection of appropriate metrology for transparent cutting edges is suggested. Further, the required measurement parameters, suitable settings, and appropriate sample preparation for the measurement of cutting edge radii of diamond grains with the above-mentioned methods are discussed. Residual stresses in the cutting tool originating from the manufacturing process affect its performance and lead to a reduced service life. In this thesis, brazed-diamond metal bonds, as found in high-performance grinding tools, are investigated through measurement techniques and simulation. During the cooling process after brazing, residual stresses arise from the mismatch of thermal expansion coefficients between the materials. In order to determine the eigenstresses in brazed diamond tools due to their manufacturing process, a thermomechanically coupled finite element method (FEM) calculation for the brazing process is conducted. The complete stress tensor for verification of the simulation cannot be obtained experimentally through Ramanspectroscopy. Therefore, the expected peak shifts of the Raman-spectra are calculated from the simulated stress tensors and compared with the experiments. XV
5 Zusammenfassung Zusammenfassung Ein vertieftes Verständnis der Physik von Bearbeitungsprozessen hilft, die Entwicklung neuer Prozesse und neuer Schneidwerkzeuge voranzutreiben. Die vorliegende Arbeit beinhaltet die Entwicklung und Bereitstellung von Simulationswerkzeugen für das Verständnis und die methodische Verbesserung von Schneidprozessen. Dies geschieht unter der Berücksichtigung von vorgängigen Schäden am Werkzeug aufgrund von dessen Herstellung, welche bis heute nicht ausreichend in der Forschung und Entwicklung behandelt werden. Weiter gibt diese Arbeit Einblick in die prozessinduzierten Lasten auf das Werkzeug und deren Abhängigkeit von der Werkzeuggeometrie durch thermomechanische Simulation der Zerspanung mit definierten und nicht definierten Geometrien. Für alle Prozesssimulationsansätze müssen Material- und Systemdaten identifiziert oder geschätzt werden. Insbesondere bei der Simulation von Schneidprozessen ist dies eine Herausforderung, da kein standardisiertes experimentelles Verfahren zur Parameteridentifikation existiert. Deshalb wird eine inverse Materialmodellierung zur Bestimmung der Material- und Systemdaten eingesetzt. Die dafür benötigten Simulationswerkzeuge werden in der vorliegenden Arbeit hergeleitet. Schleifen zum Beispiel ist einer der komplexesten Bearbeitungsprozesse, dessen Modellierbarkeit durch die stochastische Natur des Einzelkorneingriffs begrenzt wird. Thermomechanische Analysen der Interaktion zwischen Schleifkorn und Werkstückmaterial tragen dazu bei, den komplexen Schleifprozess besser zu verstehen. Schneidkantenradien der Schneidwerkzeuge, beeinflussen den Zerspanungsprozess sowie auch das Werkzeugverschleissverhalten grundlegend, was auch für die einzelnen Schleifkörner gilt. Analysen der Schneidkantenradien auf den Diamantkörnern sind daher eine unabdingbare Voraussetzung für die Modellierung. Daher zeigt diese Arbeit auf, mit welchen Methoden Schneidkantenradien auf Diamanten vermessen werden können und vergleicht diese miteinander. Wichtige Themen in der Simulation des Schneidprozesses sind die thermischen Einflüsse auf das Werkzeug und das Werkstück. Zur realitätsnahen Simulation des Zerspanungsprozesses muss die thermomechanische Kopplung immer mitberücksichtigt werden. Daneben ist es infolge der grossen plastischen Verformungen des Werkstückmaterials notwendig, Materialschädigungen innerhalb der konstitutiven Gleichungen für das Werkstückmaterial zu berücksichtigen. Weitere Herausforderungen in der Simulation der Zerspanung beim Schleifen ist der stark XVI
6 Zusammenfassung negative Spanwinkel am Einzelkorn und die kleine Schnitttiefe, welche eine extrem feine Diskretisierung im numerischen Verfahren bedingt. Die Kombination numerischer Verfahren mit experimentellen Überprüfungen erzeugt einen viel detaillierteren Einblick in den Prozess des Schleifens als Experimente allein oder Numerik allein. Um den Herausforderungen der dreidimensionalen Analyse des Schneidprozesses gerecht zu werden, werden die Methode der Finiten Elemente mit updated Lagrange-Algorithmus, implizite Zeitintegration, Methoden zur lokalen Neuvernetzung, sowie ein Schädigungsmodell nach Johnson-Cook eingesetzt. Es wird festgestellt, dass sich beim Schneiden mit hohem negativen Spanwinkel, die Schnitt- und Passivkraft mit kleiner werdenden Schneidkantenradien reduzieren. Ein Johnson-Cook-Schädigungsgrenzwert von 0.7 erreicht die beste Überstimmung zwischen experimentell durch Einzelkornritzversuche und simulativ bestimmten Komponenten der Schnittkraft. Durch Variation der Schneidkantenradien kann der Einfluss von Verschleiss genähert untersucht werden. Allerdings ist die experimentelle Erfassung der Schneidkanten selbst eine Herausforderung zumal die Transparenz, das Reflektionsvermögen sowie die Abrasivität von Diamantschleifkörnern sowohl für optische als auch berührende Messverfahren ein Hindernis darstellen. Die Methode von Wyen kann für die Charakterisierung der Schneidkante mittels eines Radius aus den dann gemessenen Rohdaten angewendet werden. In dieser Arbeit werden verschiedene Messverfahren angewendet und miteinander verglichen, nämlich taktile Messung auf einem Profilometer, konfokale und Fokus-Variations-Lichtmikroskopie, Abdrucktechnik mit optischer Vermessung, Stereo-Rasterelektronenmikroskopie (SEM), und Rasterkraftmikroskopie (AFM). Aufgrund dieser Messungen wird ein Vorgehen zur Auswahl der geeigneten Messtechnik bei transparenten Schneiden vorgeschlagen. Weiter werden die notwendigen Messparameter, geeigneten Einstellungen und korrekte Probenvorbereitung für die Messung von Schneidkantenradien von Diamantkörnern mittels der genannten Messmittel diskutiert. Restspannungen im Schleifwerkzeug aus der Herstellung sind im Einsatz nachteilig und reduzieren die Lebensdauer. In dieser Arbeit werden gelötete Diamant-Metall-Verbindungen, wie sie in Hochleistungsschleifwerkzeugen verwendet werden, messtechnisch und simulativ untersucht. Beim Abkühlen nach dem Löten ergeben sich Restspannungen als Folge der unterschiedlichen thermischen Ausdehnungskoeffizienten der beteiligten Materialien. XVII
7 Zusammenfassung Um die Eigenspannungen in den gelöteten Diamantwerkzeugen aufgrund ihrer Herstellungsverfahren zu berechnen, wird eine thermomechanisch gekoppelte FEM-Rechnung des Lötprozesses durchgeführt. Der vollständige Spannungstensor lässt sich aus den Daten der Raman Spektroskopie nicht berechnen, wie es für die experimentelle Verifikation der Simulation nötig wäre. Daher werden aus den simulierten Spannungstensoren die zu erwartenden Peak-Verschiebungen der Raman-Spektra berechnet und mit den Experimenten verglichen XVIII
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