Universität Stuttgart
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Item Open Access Glass fracture during micro-scratching(2020) Zakiev, Islam; Gogotsi, George A.; Storchak, Michael; Zakiev, VadimThe regularity of glass surface fracture and resistance to destruction were investigated by the methods of progressive and static microscratching with the Berkovich indenter. The research hardware was the original nanoindentation/microscratching devices and a non-contact interference profilometer for studying the morphology of the formed microscratches. The regularities of the fracture stages and the cracks growth along the microscratch were established depending on the indenter applied load. Based on analysis of the microcracks profile formed at various loads on the indenter immediately after the process of applying these scratches and after several hours of rest, it was found that the process of crack propagation along the scratch continues for a long time. Taking into account this established fact, a discrete-statistical method of the cracks formation for a long time is proposed. In accordance with this method, scratching is carried out with a constant load on short and separated tracks. The load on the indenter in each track increases discretely with a certain step. The influence of the medium on the scratching process is analyzed. The breaking mechanism in the glasses scratching process is formulated as the load on the indenter increases, and a model of the glass fracture stages is proposed.Item Open Access Interaction of mechanical characteristics in workpiece subsurface layers with drilling process energy characteristics(2024) Storchak, Michael; Hlembotska, Larysa; Melnyk, Oleksandr; Baranivska, NataliiaThe performance properties of various types of parts are predominantly determined by the subsurface layer forming methods of these parts. In this regard, cutting processes, which are the final stage in the manufacturing process of these parts and, of course, their subsurface layers, play a critical role in the formation of the performance properties of these parts. Such cutting processes undoubtedly include the drilling process, the effect of which on the mechanical characteristics of the drill holes subsurface layers is evaluated in this study. This effect was evaluated by analyzing the coincidence of the energy characteristics of the short hole drilling process with the mechanical characteristics of the drilled holes’ subsurface layers. The energy characteristics of the short-hole drilling process were the total drilling power and the cutting work in the tertiary cutting zone, which is predominantly responsible for the generation of mechanical characteristics in the subsurface layers. As mechanical characteristics of the drill holes’ subsurface layers were used, the microhardness of machined surfaces and total indenter penetration work determined by the instrumented nanoindentation method, as well as maximal indenter penetration depth, were determined by the sclerometry method. Through an analysis of the coincidence between the energy characteristics of the drilling process and the mechanical characteristics of the subsurface layers, patterns of the effect of drilling process modes, drill feed, and cutting speed, which essentially determine these energy characteristics, on the studied mechanical characteristics have been established. At the same time, the increase in the energy characteristics of the short-hole drilling process leads to a decrease in the total indenter penetration work and the maximum indenter penetration depth simultaneously with an increase in the microhardness of the drilled holes’ subsurface layers.Item Open Access Determination of the shear angle in the orthogonal cutting process(2022) Storchak, Michael; Stehle, Thomas; Möhring, Hans-ChristianDetermination of the shear angle by experimental and analytical methods, as well as by numerical simulation, is presented. Experimental determination of the shear angle was performed by analyzing the chip roots obtained by the method of cutting process quick stop through purposeful fracture of the workpiece in the area surrounding the primary cutting zone. The analytical determination of the shear angle was carried out using the chip compression ratio and was based on the principle of a potential energy minimum. Measurement of the shear angle in the numerical simulation of orthogonal cutting was performed using the strain rate pattern of the machined material at the selected simulation moment. It was analyzed how the parameters of the Johnson-Cook constitutive equation and the friction model affect the shear angle value. The parameters with a predominant effect on the shear angle were determined. Then the generalized values of these parameters were established with a software algorithm based on identifying the intersection of the constitutive equation parameter sets. The use of generalized parameters provided the largest deviation between experimental and simulated shear angle values from 9% to 18% and between simulated and analytically calculated shear angle values from 7% to 12%.Item Open Access Cutting process consideration in dynamic models of machine tool spindle units(2023) Danylchenko, Yurii; Storchak, Michael; Danylchenko, Mariia; Petryshyn, AndriiReducing the deviation effect from the specified machining conditions on the quality of the process in real time is the desired result of the intelligent spindle control system. To implement such a control system, a dynamic interaction model of the technological machining system with the cutting process was developed. The transfer matrix method of a multibody system was used in the development of the dynamic model. The physical closure condition of the technological machining system for using the transient matrix method is implemented in the developed model by introducing into this model an additional elastic coupling of the contact between the tool and the machined workpiece. The model is presented as a dynamic model of the elastic system “spindle unit-workpiece/tool-cutting process-ool/workpiece”. To develop the dynamic model, the system decomposition was performed with an analytical description of the joint deformation conditions of the subsystems and the use of the transient matrix method to calculate the harmonic influence coefficients of these subsystems. The proposed approach is used to calculate the native vibration frequencies of the spindle with the workpiece fixed in the chuck and supported with the tool. The calculation results correspond to the experimental ones and quite accurately represent their trends for different contact interaction conditions.Item Open Access Determination of chip compression ratio for the orthogonal cutting process(2024) Storchak, MichaelThe chip compression ratio is the most important characteristic of various machining processes with chip generation. This characteristic enables the determination of kinetic and other energy loads on the tool and the machined material. This provides an overall evaluation of the machining process and the possibility of its subsequent optimization. This paper presents the results of determining this cutting characteristic by experimental method, analytical calculation, and numerical modeling. For the analytical calculation of the chip compression ratio, an analytical cutting model developed based on the variational principle of the minimum potential energy was used. A finite element model of orthogonal cutting was used for the numerical simulation of the above process characteristic. Experimentally, the chip compression ratio was determined by the ratio of the chip thickness to the cutting depth (undeformed cutting thickness). The chip thickness was determined by direct measurement using chip slices obtained during the cutting process. The Johnson-Cook constitutive equation was used as the machined material model and the Coulomb model was used as the friction model. The generalized parameters’ determination of the constitutive equation was performed through a DOE (Design of Experiment) sensitivity analysis. The variation range of these parameters was chosen based on the analysis of the effect of individual parameters of the constitutive equation on the chip compression ratio value. The largest deviations between the experimental and analytically calculated values of the chip compression ratio did not exceed 21%. At the same time, the largest deviations of simulated values of the indicated cutting characteristic and its experimental values did not exceed 20%. When comparing the experimental values of the chip compression ratio with the corresponding calculated and simulated values, the deviations were within 22%.