Modeling of machining process of EB-PVD ceramic coatings using discrete element method

Date
2022-08
Language
American English
Embargo Lift Date
Committee Members
Degree
Degree Year
Department
Grantor
Journal Title
Journal ISSN
Volume Title
Found At
Elsevier
Can't use the file because of accessibility barriers? Contact us with the title of the item, permanent link, and specifics of your accommodation need.
Abstract

In this work, a new discrete element model (DEM) for simulating the machining process of thermal barrier coatings is presented. The effects of cutting processing parameters, including cutting depth and cutting speed, on the cutting force and chip morphology are studied. In the model, a columnar grain microstructure mimicking the electron-beam physical vapor deposition (EB-PVD) coating is used. The results show that, as the cutting depth increases, the cutting chip morphology changes from fine powder form (ductile mode) to large chuck pieces (brittle mode). The transition depth or the critical cutting depth is determined based on the Griffith fracture criterion. The transition is also illustrated using the numbers of broken bonds and cutting energy changes in the DEM model. In the ductile mode, the number of broken bonds is increased gradually. In contrast, at larger cutting depths, the brittle mode causes a step-wise increase. Moreover, the maximum cutting force is found correlated to the cutting depth, which agrees well with an analytical solution based on fracture mechanics principles. The period in the cutting force is consistent with the diameter of the column grain. Finally, the cutting speed has little effect on the cutting force and chip morphology due to no strain rate sensitivity.

Description
item.page.description.tableofcontents
item.page.relation.haspart
Cite As
Zhang, J., Sagar, S., Dube, T., Yang, X., Choi, H., Jung, Y.-G., Koo, D. D., & Zhang, J. (2022). Modeling of machining process of EB-PVD ceramic coatings using discrete element method. CIRP Journal of Manufacturing Science and Technology, 38, 581–589. https://doi.org/10.1016/j.cirpj.2022.05.018
ISSN
Publisher
Series/Report
Sponsorship
Major
Extent
Identifier
Relation
Journal
CIRP Journal of Manufacturing Science and Technology
Source
Author
Alternative Title
Type
Article
Number
Volume
Conference Dates
Conference Host
Conference Location
Conference Name
Conference Panel
Conference Secretariat Location
Version
Author's manuscript
Full Text Available at
This item is under embargo {{howLong}}