Doctor of Philosophy / Department of Industrial & Manufacturing Systems Engineering / Zhijian Pei / Poor machinability of hard-to-machine materials (such as advanced ceramics and titanium) limits their applications in industries. Ultrasonic-vibration-assisted grinding (UVAG), a hybrid machining process combining material-removal mechanisms of diamond grinding and ultrasonic machining, is one cost-effective machining method for these materials. Compared to ultrasonic machining, UVAG has much higher material removal rate while maintaining lower cutting pressure and torque, reduced edge chipping and surface damage, improved accuracy, and lower tool wear rate. However, physics-based models to predict cutting force in UVAG have not been reported to date. Furthermore, edge chipping is one of the technical challenges in UVAG of brittle materials. There is no report related to effects of cutting tool design on edge chipping in UVAG of brittle materials. The goal of this research is to provide new knowledge of machining these hard-to-machine materials with UVAG for further improvements in machining cost and surface quality. First, a thorough literature review is given to show what has been done in this field. Then, a physics-based predictive cutting force model and a mechanistic cutting force model are developed for UVAG of ductile and brittle materials, respectively. Effects of input variables (diamond grain number, diamond grain diameter, vibration amplitude, vibration frequency, spindle speed, and federate) on cutting force are studied based on the developed models. Interaction effects of input variables on cutting force are also studied. In addition, an FEA model is developed to study effects of cutting tool design and input variables on edge chipping. Furthermore, some trends predicted from the developed models are verified through experiments. The results in this dissertation could provide guidance for choosing reasonable process variables and designing diamond tools for UVAG.

No description available.

Burrs are rough protrusions that form along the edge of a component during processing and are commonly produced during machining. Generally, the presence and severity of a burr directly impacts the final part quality. Thus, burrs need to be removed in subsequent processes to avoid injury when handling a part and/or negatively impacting the part's functionality. The size, shape, and nature of the attachment of the burr to the cutting edge are highly dependent on the material, tooling, and process parameters used during machining. This research aimed to develop two new approaches to minimize and/or eliminate burr formation during the drilling of ductile materials. The first new method outlined in this thesis relates to injecting materials in different forms at high pressures under the workpiece on the side from which the drilling tool exits to support the drilling thrust force and thereby minimize exit burr formation. The second method introduced a novel technique for designing and testing highly effective step drills based on the workpiece material and cutting parameters, using commercial drills. Testing the two approaches showed promising results for producing comparatively smaller exit burrs. / Thesis / Master of Applied Science (MASc)

Le travail présenté a pour objectif la prédiction numérique de la résistance résiduellede grandes structures vis-à-vis d’évènements accidentels, tels que ceux rencontrés p.ex. dans le cas de la collision de navires ou d’impact d’oiseaux en aéronautique. Cesévènements peuvent dans certain cas conduire à la rupture, qui est ici considéréeductile. La difficulté de cette étude, consiste à reproduire dans une méthodologieunifiée basée sur la méthode des éléments finis les étapes successives menant àla ruine ultime de la structure. Ces étapes sont : l’endommagement ductile, lalocalisation de la déformation et la propagation de la fissure. Un élément essentiel pour la conception d’un modèle de fissuration ductile prédictif est le traitement numérique de la phase transitoire critique de localisation de la déformation induite par l’endommagement dans une bande de matière étroite.A cet effet, trois points de vue différents en termes de champ de déplacement àtravers la bande de localisation sont proposés. Ces trois approches se distinguentpar le type de discontinuité considérée : forte, faible et régularisée (expression nonlinéaire). Un cadre variationnel consistant est élaboré pour chacune des trois approches.Ainsi la cinématique enrichie est incorporée dans la formulation de l’élément fini enutilisant la méthode des éléments finis enrichis (X-FEM). Puis, la performance deces méthodes est évaluée vis-à-vis de leur capacité à modéliser la phase transitoireentre endommagement diffus (mécanique des milieux continus) et propagation defissure (mécanique de la rupture). Ces travaux sont réalisés dans le contexte dematériaux ductiles. D’après les analyses réalisées, la combinaison du modèle de ’discontinuité fortecohésive’ et la X-FEM semble être la plus prometteuse des trois approches étudiéespour allier physique et numérique. Le développement d’un tel modèle est discutéen détail. Enfin, deux critères supplémentaires sont définis : le premier pour lepassage de l’endommagement diffus au modèle de bande cohésive et un deuxièmepour le passage du modèle de bande cohésive à la rupture. / The present work aims at numerically predicting the current residual strengthof large engineering structures made of ductile metals regarding accidental events,e.g. ships collision or bird strike in aviation, which may potentially lead to failure.With this aim in view, the challenge consists in reproducing within a unified finiteelement (FE)-based methodology the successive steps of micro-voiding-induceddamage, strain localization and crack propagation, if any.A key ingredient for a predictive ductile fracture model is the proper numericaltreatment of the critical transition phase of damage-induced strain localizationinside a narrow band. For this purpose, three different viewpoints in terms ofdisplacement field across the localization band are proposed involving a strong,weak and (non-linearly) regularized discontinuity, respectively.A consistent variational framework is elaborated for each of the three methods,whereby the enriched kinematics is embedded into the FE formulation using theeXtended FEM. Then, within a comparative procedure, the performance of thesemethods is assessed regarding their ability of modeling the transition phase betweendiffuse damage (continuum mechanics framework) and crack propagation (fracturemechanics framework), always in the context of ductile materials.According to the aforementioned analyses, the combination of the strong discontinuitycohesive model and the X-FEM appears to be the most promising of thethree studied approaches to bring together physics and numerics. The developmentof such a model is discussed in detail. Finally, two supplementary criteria aredefined: the first one for the passage from diffuse damage to the cohesive bandmodel and the second one for the passage from the cohesive band model to thecrack.

Functionally graded materials (FGMs) are composites with continuous material property variations. The distinct interfaces between the reinforcement and the matrix in classical composites are potential damage initiation sites. The concept of FGM aims at avoiding the material mismatch at the interfaces. Functionally graded materials originated from the need for a material that has high-toughness at very high operating temperatures that occur in rocket nozzles and aeroplane engines. One of the early applications of graded materials can be thus found in thermal barrier coatings of gas turbine blades. Recent applications of FGMs include optoelectronics, ballistic impact resistance structures, wear resistant coatings and others. Although the manufacturing and applications of FGMs are well developed the basic mechanics of failure is not well understood, which is important in developing engineering design methodologies. Modern day design practice uses the concepts of fracture mechanics and the fracture properties of graded materials is not well understood. Most studies in the literature have assumed that the material response of the bulk functionally graded material to be elastic even though the constituents are nominally ductile. Some asymptotic analysis available in the literature have described the effect of ductility on the fracture parameters. However, these analysis are not complete in the sense that they have some undetermined constants. The present thesis aims at performing whole-field finite element (FE) simulations of a crack embedded in a ductile functionally graded material subjected to an anti-plane shear (mode-3) loading. A J2-deformation theory based power-law hardening nonlinear material response is assumed. The material property variation is assumed to be in the radial-direction (r-FGM), tangential to the crack (x-FGM), normal to the crack plane (y-FGM) and also at an arbitrary angle to the crack-plane (xy-FGM). Yet another power law described the material property variation. The competition between the indices of the hardening and material property variation is understood by performing a parametric analysis by varying both systematically. Our results indicate that the first most singular term of the asymptotic series remains unaffected. For some values of the material property variation index, the second asymptotic term is affected. The semi-closed form solutions available in the literature were unable to decipher the relative range of dominance of the first and second terms. From the present whole-field FEM analysis were able to extract this relative range of dominance. Our results indicate the range of dominance of the first term is least for FGMs when the material property variation is in the direction to the crack (x-FGM), and it is more for y-FGM.

Experimental studies have shown that the yield strength of many important engineering materials such as polymers, ceramics and metallic glasses is dependent on hydrostatic stress. In addition, these materials may also exhibit plastic dilatancy. These deviations from the assumptions of classical plasticity theories have also been observed for some metallic alloys, although to a lesser extent compared to non-metals. In pressure independent plastic solids, it has been found that the level of crack tip constraint can affect the near-tip stress and deformation fields and hence the fracture resistance. The objective of the present work is to study the effects of pressure sensitive yielding, plastic dilatancy and constraint loss on the ductile fracture processes under mode-I conditions. Further, the three-dimensional (3D) structure of elastic-plastic near-crack front fields in a pressure independent plastic solid under mixed mode (combined modes I and II) loading is also examined. A finite element study of 3D crack tip fields in pressure sensitive plastic solids under mode-I, small scale yielding (SSY) conditions is first carried out. The material is assumed to obey a small strain, Extended Drucker-Prager (EDP)yield criterion. The roles of pressure sensitive yielding, plastic dilatancy and yield locus shape on the 3D plastic zone development and near-crack front fields are systematically investigated. It is found that while pressure sensitivity leads to a significant drop in the hydrostatic stress all along the 3D crack front, it enhances the plastic strain and crack opening displacements. However, plastic incompressibility results in elevation of both near-tip hydrostatic stress and notch opening. The implications of these observations on micro-void growth and interaction near a notch tip are studied in detail subsequently. The effects of constraint loss on void growth near a notch tip under mode-I loading in materials exhibiting pressure sensitive yielding and plastic dilatancy are investigated by performing large deformation elastic-plastic finite element analyses. To this end, two-dimensional (2D)plane strain and 3Dmodified boundary layer formulations are employed by prescribing the elastic K-T field as remote boundary conditions. The results are generated for different combinations of K (or J ) and T -stress. The material is assumed to obey a finite strain, EDP yield condition. The distributions of hydrostatic stress and plastic strain in the ligament connecting the notch and a nearby void (cylindrical or spherical) as well as the growth of the notch and the void are studied. The results show that void growth with respect to J is enhanced due to pressure sensitivity, and more so when the plastic flow is non-dilatational, which corroborates with the trends exhibited by the 3D crack tip fields. However, the evolution of ductile fracture processes like void growth, plastic strain localization and ligament length reduction with respect to J is retarded in the case of spherical voids. Further, irrespective of pressure sensitivity, loss of crack tip constraint can significantly slow down void growth. The effects of pressure sensitive yielding and plastic dilatancy on near-tip void growth and multiple void interaction mechanisms in single edge notched bend (SENB) and center cracked tension (CCT) specimens which display high and low constraint levels, respectively, are investigated next. It is observed that the latter mechanism which is favored by high initial porosity is further accelerated by pressure sensitive yielding and high constraint. The predicted resistance curves based on a simple void coalescence mechanism show enhancement in fracture resistance when constraint level is low and when pressure sensitivity is suppressed. Finally, detailed elastic-plastic finite element simulations are carried out using a boundary layer (SSY) formulation to investigate the 3D nature of near-crack front fields in a von Mises solid under mixed mode (combined modes I and II)loading. The plastic zones and radial, angular and thickness variations of the stresses are studied corresponding to different levels of remote elastic mode mixity and applied load, as measured by the plastic zone size with respect to the plate thickness. The 3D results are compared with those obtained from 2D simulations and asymptotic solutions to establish the validity of 2D plane stress and plane strain approximations near a crack front. It is found that, in general, plane stress conditions prevail at a distance from the crack front exceeding half the plate thickness, although it could be slightly smaller for mode-II predominant loading.

The failure mechanism in ductile materials involves void nucleation, their growth and subsequent coalescence to form the fracture surface. The voids are generated due to fracture or debonding of second phase particles or at slip band intersections. The triaxial stress field prevailing around a crack tip and in the necking region strongly influences the growth of these voids. In the initial stages of deformation, these microscale voids are often sufficiently small so that they exist entirely within a single grain of a polycrystalline material. Further, single crystals are used in high technology applications like turbine blades. This motivates the need to study void growth in a single crystal while investigating ductile fracture. Thus, the objectives of this work are to analyze the interaction between a notch tip and void as well as the growth and coalescence of a periodic array of voids under different states of stress in ductile FCC single crystals. First, the growth of a cylindrical void ahead of a notch tip in ductile FCC single crystals is studied. To this end, 2D plane strain finite element simulations are carried out under mode I, small scale yielding conditions, neglecting elastic anisotropy. In most of these computations, the orientation of the FCC single crystal is chosen so that notch lies in the (010) plane, with notch front along the [101] direction and potential crack growth along [101]. This orientation has been frequently observed in experimental studies on fracture of FCC single crystals. Three equivalent slip systems are considered which are deduced by combining three pairs of 3D conjugate slip systems producing only in-plane deformation. Attention is focused on the effects of crystal hardening, ratio of void diameter to spacing from the notch on plastic flow localization in the ligament connecting the notch and the void as well as their growth. The results show strong interaction between slip shear bands emanating from the notch and angular sectors of single slip forming around the void leading to intense plastic strain development in the ligament. However, the ductile fracture processes are retarded by increase in hardening of the single crystal and decrease in ratio of void diameter to spacing from the notch. In order to examine the effect of crystal orientation, computations are performed with an orientation wherein the three effective slip systems are rotated about the normal to the plane of deformation. A strong influence of crystal orientation on near-tip void growth and plastic slip band development is observed. Further, in order to study the synergistic, cooperative growth of multiple voids ahead of the notchtip, an analysis is performed by considering a series of voids located ahead of the tip. It is found that enhanced void growth occurs at higher load levels as compared to the single void model. Next, the growth and coalescence of a periodic array of cylindrical voids in a FCC single crystal is analyzed under different stress states by employing a 2D plane strain, unit cell approach. The orientation of the crystal studied here considers [101] and [010] crystal directions along the minor and major principal stress directions, respectively. Three equivalent slip systems, similar to those in the notch and void simulations are taken into account. Fringe contours of plastic slip and evolution of macroscopic hydrostatic stress and void volume fraction are examined. A criterion for unstable void growth which leads to onset of void coalescence is established. The effects of various stress triaxialities, initial void volume fraction and hardening on void growth and coalescence is assessed. It is observed that plastic slip activity around the void intensifies with increase in stress triaxiality. The macroscopic hydrostatic stress increases with deformation, reaches a peak value and subsequently decreases rapidly. An increase in stress triaxiality enhances the macroscopic hydrostatic stress sustained by the unit cell and promotes void coalescence. The stress triaxiality also has a profound effect on the shape of the void profile. The values of critical void volume fraction and critical strain, which mark onset of void coalescence, decrease within crease in stress triaxiality. However, the onset of void coalescence is delayed by increase in hardening and decrease initial void volume fraction.