State of the art in finite element approaches for milling process: a review

doi:10.1007/s40436-022-00417-x

Advances in Manufacturing ›› 2023, Vol. 11 ›› Issue (4): 708-751.doi: 10.1007/s40436-022-00417-x

• • 上一篇

State of the art in finite element approaches for milling process: a review

Shailendra Chauhan, Rajeev Trehan, Ravi Pratap Singh

Department of Industrial and Production Engineering, Dr. B R Ambedkar National Institute of Technology, Jalandhar, Punjab, India

收稿日期:2022-02-17 修回日期:2022-04-09 发布日期:2023-10-27
通讯作者: Ravi Pratap Singh,E-mail:singhrp@nitj.ac.in E-mail:singhrp@nitj.ac.in
作者简介:Shailendra Chauhan is currently pursuing Ph.D. in the Department of Industrial & Production Engineering at Dr. B. R. Ambedkar National Institute of Technology, Jalandhar, Punjab, India. He has received the M.E. in Mechanical Engineering (Manufacturing Technology) from the Department of Mechanical Engineering, NITTTR, Chandigarh, India. His broad areas of research are; manufacturing processes, milling operation, advanced materials, and their processing, optimization and modeling, etc.
Dr. Rajeev Trehan is currently working as an Associate Professor and Head of the Department in Industrial and Production Engineering at Dr. B. R. Ambedkar National Institute of Technology Jalandhar, India. His areas of interest are quality management, supply chain management, industrial management, and systems dynamics. He has over 28 years of industry and teaching experience. He has published his work in international and national journals and proceedings of international conferences to his credit. Dr. Trehan has organized several international conferences at NIT Jalandhar as chairman and convener.
Dr. Ravi Pratap Singh is presently working as an Assistant Professor in the Department of Industrial & Production Engineering at Dr. B. R. Ambedkar National Institute of Technology, Jalandhar, Punjab, India. Prior to this, he has also served the Department of Technical Education, Uttar Pradesh, India for about 2 years. He has received the Doctor of Philosophy (Ph.D.) degree in the area of Rotary Ultrasonic Machining of Advanced Engineering Materials, and M.Tech. in Mechanical Engineering (Industrial and Production Engineering) from the Department of Mechanical Engineering, National Institute of Technology, Kurukshetra (Haryana), India. He is a Life Member of Indian Institution of Industrial Engineering (IIIE), Mumbai, India, and SCIence and Engineering Institute (SCIEI), Log Angeles, USA. Dr Singh is also a Senior Member of Indian Society of Mechanical Engineers (ISME), Chennai, India. He has published more than 100 research articles throughout the several SCI/Scopus indexed journal, including International/National level conferences. He is also academically engaged with the editorship and reviewership with the several SCI/Scopus indexed Journals from last 9–10 years. He is also a Guest Editor of World Journal of Engineering (Emerald Publications), International Journal of Sustainable Materials and Structural Systems, and the International Journal of Six Sigma and Competitive Advantage (Inderscience Publisher). Dr. Singh has organized several national/international conferences at NIT Jalandhar as a convener/organizing secretary/session coordinator, etc. Besides research excellence, He has been awarded as Young Scientist in Mechanical Engineering in VIRA-2019 awards, as Young Faculty in Engineering (Major Area: Mechanical Engineering) in VIFA-2019 awards, and as Best Researcher Award in 4th International Scientist Awards on Engineering, Science, and Medicine during January 2020 in New Delhi, India. He has delivered several Expert Talks/Lectures at a diferent level of the platform throughout the country. He has also been nominated as General Chair Reviewer, Technical Program Committee, National Advisory Committee, etc. during various national/international events held in China, Norway, and India. In addition to this, he is also serving as an Ambassador of Bentham Open, Sharjah, UAE as well as a Member of the Visor Academic Committee, Singapore. Dr. Singh has also been ranked among the top 2% of Scientists in the world as per the survey conducted by STANFORD University for the year 2021.

State of the art in finite element approaches for milling process: a review

Shailendra Chauhan, Rajeev Trehan, Ravi Pratap Singh

Department of Industrial and Production Engineering, Dr. B R Ambedkar National Institute of Technology, Jalandhar, Punjab, India

Received:2022-02-17 Revised:2022-04-09 Published:2023-10-27
Contact: Ravi Pratap Singh,E-mail:singhrp@nitj.ac.in E-mail:singhrp@nitj.ac.in

摘要/Abstract

摘要： Over a century, metal cutting has been observed as a vital process in the domain of manufacturing. Among the numerous available metal-cutting processes, milling has been considered as one of the most employable processes to machine a variety of engineering materials productively. In the milling process, material removal occurs when the workpiece is fed against a rotating tool with multiple cutting edges. In order to maximize the profitability of metal cutting operations, it is essential that the various input and output variable relationships are analyzed and optimized. The experimental method of studying milling processes is costly and time demanding, particularly when a large variety of elements such as cutting tool shape, materials, cutting conditions, and so on, are included. Due to these issues, other alternatives emerged in the form of mathematical simulations that employ numerical methods. The finite element approaches have well-proven to be the most practical and commonly utilized numerical methods. The finite element model (FEM) can be used to determine the various physical interactions occurring during the machining process along with the prediction of various milling characteristics, such as cutting forces, cutting temperature, stresses, etc., with the help of milling inputs. In the present article, various research studies in the broad milling process domain practiced with numerous finite element approaches have been critically reviewed and reported. It further highlights the several experimental and finite element approaches-based research studies that attempted to analyze and optimize the overall performance of the different milling processes. In recent years, various investigators have explored numerous ways to enhance milling performance by probing the different factors that influence the quality attributes. Some of the studies have also been found to be focused on the economic impacts of milling and various process inputs that affect milling performance. Furthermore, various milling factors’ impact on the performance characteristics are presented and critically discussed. The issues related to the recent improvements in tool-work interaction modeling, experimental techniques for acquiring various milling performance measures, and the aspects of turn and micro-milling with finite element-based modeling have been further highlighted. Among the various available classifications in the milling process as employed in industries, face milling is more strongly established compared to other versions such as end milling, helical milling, gear milling, etc. The final section of this research article explores the various research aspects and outlines future research directions.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-022-00417-x

关键词: Milling, Finite element modeling (FEM), Micro milling, Turn-milling

Abstract: Over a century, metal cutting has been observed as a vital process in the domain of manufacturing. Among the numerous available metal-cutting processes, milling has been considered as one of the most employable processes to machine a variety of engineering materials productively. In the milling process, material removal occurs when the workpiece is fed against a rotating tool with multiple cutting edges. In order to maximize the profitability of metal cutting operations, it is essential that the various input and output variable relationships are analyzed and optimized. The experimental method of studying milling processes is costly and time demanding, particularly when a large variety of elements such as cutting tool shape, materials, cutting conditions, and so on, are included. Due to these issues, other alternatives emerged in the form of mathematical simulations that employ numerical methods. The finite element approaches have well-proven to be the most practical and commonly utilized numerical methods. The finite element model (FEM) can be used to determine the various physical interactions occurring during the machining process along with the prediction of various milling characteristics, such as cutting forces, cutting temperature, stresses, etc., with the help of milling inputs. In the present article, various research studies in the broad milling process domain practiced with numerous finite element approaches have been critically reviewed and reported. It further highlights the several experimental and finite element approaches-based research studies that attempted to analyze and optimize the overall performance of the different milling processes. In recent years, various investigators have explored numerous ways to enhance milling performance by probing the different factors that influence the quality attributes. Some of the studies have also been found to be focused on the economic impacts of milling and various process inputs that affect milling performance. Furthermore, various milling factors’ impact on the performance characteristics are presented and critically discussed. The issues related to the recent improvements in tool-work interaction modeling, experimental techniques for acquiring various milling performance measures, and the aspects of turn and micro-milling with finite element-based modeling have been further highlighted. Among the various available classifications in the milling process as employed in industries, face milling is more strongly established compared to other versions such as end milling, helical milling, gear milling, etc. The final section of this research article explores the various research aspects and outlines future research directions.

The full text can be downloaded at https://link.springer.com/article/10.1007/s40436-022-00417-x

Key words: Milling, Finite element modeling (FEM), Micro milling, Turn-milling

Shailendra Chauhan, Rajeev Trehan, Ravi Pratap Singh. State of the art in finite element approaches for milling process: a review[J]. Advances in Manufacturing, 2023, 11(4): 708-751.

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State of the art in finite element approaches for milling process: a review

State of the art in finite element approaches for milling process: a review

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