Modelling metal cutting using modern ductile fracture mechanics: Quantitative explanations for some longstanding problems

The assumption that negligible work is involved in the formation of new surfaces in the machining of ductile metals, is re-examined in the light of both current Finite Element Method (FEM) simulations of cutting and modern ductile fracture mechanics. The work associated with separation criteria in FEM models is shown to be in the kJ/m2 range rather than the few J/m2 of the surface energy (surface tension) employed by Shaw in his pioneering study of 1954 following which consideration of surface work has been omitted from analyses of metal cutting. The much greater values of surface specific work are not surprising in terms of ductile fracture mechanics where kJ/m2 values of fracture toughness are typical of the ductile metals involved in machining studies. This paper shows that when even the simple Ernst–Merchant analysis is generalised to include significant surface work, many of the experimental observations for which traditional ‘plasticity and friction only’ analyses seem to have no quantitative explanation, are now given meaning. In particular, the primary shear plane angle φ becomes material-dependent. The experimental increase of φ up to a saturated level, as the uncut chip thickness is increased, is predicted. The positive intercepts found in plots of cutting force vs. depth of cut, and in plots of force resolved along the primary shear plane vs. area of shear plane, are shown to be measures of the specific surface work. It is demonstrated that neglect of these intercepts in cutting analyses is the reason why anomalously high values of shear yield stress are derived at those very small uncut chip thicknesses at which the so-called size effect becomes evident. The material toughness/strength ratio, combined with the depth of cut to form a non-dimensional parameter, is shown to control ductile cutting mechanics. The toughness/strength ratio of a given material will change with rate, temperature, and thermomechanical treatment and the influence of such changes, together with changes in depth of cut, on the character of machining is discussed. Strength or hardness alone is insufficient to describe machining. The failure of the Ernst–Merchant theory seems less to do with problems of uniqueness and the validity of minimum work, and more to do with the problem not being properly posed. The new analysis compares favourably and consistently with the wide body of experimental results available in the literature. Why considerable progress in the understanding of metal cutting has been achieved without reference to significant surface work is also discussed.

Designs for an adaptive tuned vibration absorber with variable shape stiffness element

An adaptive tuned vibration absorber (ATVA) with a smart variable stiffness element is capable of retuning itself in response to a time-varying excitation frequency., enabling effective vibration control over a range of frequencies. This paper discusses novel methods of achieving variable stiffness in an ATVA by changing shape, as inspired by biological paradigms. It is shown that considerable variation in the tuned frequency can be achieved by actuating a shape change, provided that this is within the limits of the actuator. A feasible design for such an ATVA is one in which the device offers low resistance to the required shape change actuation while not being restricted to low values of the effective stiffness of the vibration absorber. Three such original designs are identified: (i) A pinned-pinned arch beam with fixed profile of slight curvature and variable preload through an adjustable natural curvature; (ii) a vibration absorber with a stiffness element formed from parallel curved beams of adjustable curvature vibrating longitudinally; (iii) a vibration absorber with a variable geometry linkage as stiffness element. The experimental results from demonstrators based on two of these designs show good correlation with the theory.

Modelling the cabling of rope systems

This paper presents a theoretical model of the torsional characteristics of parallel multi-part rope systems. In such systems, the ropes may cable, or wrap around each other, depending on the combination of applied torque, rope tension, length and spacing between the rope parts. Cabling constitutes a failure that might be retrievable but as such can seriously affect the performance of the rope system. The torsional characteristics of the system are very different before and after cabling, and theoretical models are given for both situations. Laboratory tests were performed on both two and four rope systems, with measurements being made of torque at rotations from 0 to 360 deg. Tests were run with different rope spacings, tensions and lengths and the results compared with predictions from the theoretical model. The conclusion from the test results was that the theoretical model predicts both the pre- and post-cabling torsional behaviour with an acceptable level of accuracy.

Modelling the torsional interaction of wire and polyester fibre ropes used for offshore moorings

Oil rig mooring lines have traditionally consisted of chain and wire rope. As production has moved into deeper water it has proved advantageous to incorporate sections of fibre rope into the mooring lines. However, this has highlighted torsional interaction problems that can occur when ropes of different types are joined together. This paper describes a method by which the torsional properties of ropes can be modelled and can then be used to calculate the rotation and torque for two ropes connected in series. The method uses numerical representations of the torsional characteristics of both the ropes, and equates the torque generated in each rope under load to determine the rotation at the connection point. Data from rope torsional characterization tests have been analysed to derive constants used in the numerical model. Constants are presented for: a six-strand wire rope; a torque-balanced fibre rope; and a fibre rope that has been designed to be torque-matched to stranded wire rope. The calculation method has been verified by comparing predicted rotations with measured test values. Worked examples are given for a six-strand wire rope connected, firstly, to a torque-balanced fibre rope that offers little rotational restraint, and, secondly, to a fibre rope whose torsional properties are matched to that of the wire rope.

Modelling fatigue damage distribution to inform slip and cut policy for riser tensioner ropes

The paper describes a method whereby the distribution of fatigue damage along riser tensioner ropes is calculated, taking account of heave motion, set tension, system geometry, tidal range and rope specification. From these data the distribution of damage along the rope is calculated for a given time period using a Miner’s summation method. This information can then be used to help the operator decide on the length of rope to ‘slip and cut’ whereby a length from the end of the rope is removed and the rope moved through the system from a storage drum such that sections of rope that have already suffered significant fatigue damage are not moved to positions where there is another peak in the distribution. There are two main advantages to be gained by using the fatigue damage model. The first is that it shows the amount of fatigue damage accumulating at different points along the rope, enabling the most highly damaged section to be removed well before failure. The second is that it makes for greater efficiency, as damage can be spread more evenly along the rope over time, avoiding the need to scrap long sections of undamaged rope.