A State of the Art on Simulation and Modelling Methods in Machining: Future Prospects and Challenges

Abstract

AbstractSimulation modelling methods have gained dramatic acceleration in the last years among academic environments and industry-driven enterprises. Primary reason is that such models have great potential in predicting of machining process parameters. Therefore, tis study evaluates the place and capability of these models in fundamental machining operations. In this direction, Finite Element Modelling Methods are discussed by questioning their contributions to the process performance. Despite numerous positive aspects, development of a successful model is highly difficult owing to the complexity of machining environment with variation of thermo-mechanical effect, tribological conditions, interaction of process variables and high deformation rate of materials etc. Therefore, a critical assessment of the merits and drawbacks of each method associating with their basic phenomena has been investigated. Predictive models basically aim to estimate the machinability characteristics such as stress–stain rates, cutting forces and temperatures etc. Nevertheless, practical applications require correlations between these characteristics and performance outcomes such as surface integrity of part, tool wear index, chip morphology, dimensional accuracy etc. In the end, the molecular dynamics and smoothed particle hydrodynamics have been discussed. Thus, this paper is expected to contribute to up-to-date studies by criticizing the key findings of the predictive models in machining processes.