The paper addresses the need for innovation in order to achieve sustainable growth and business development within the manufacturing industry, and further how that can be enabled by striving towards functions. Adopting an open perspective, the paper proposes a function innovation model involving academia, potential function providers and customers in order to create a long-term win-win situation between function providers and their customers.

A dislocation density material model based on model-based-phenomenology has been used to predict orthogonal cutting of stainless steel Sanmac 316L. The chip morphology and the cutting forces are used to validate the model. The simulated cutting forces and the chip morphology showed good conformity with practical measurements. Furthermore, simulation of cutting process utilizing the dislocation density based material model improved understanding regarding material behaviour such as strain hardening and shear localization at the process zone.

The modelling of metal cutting has proved to be particularly complex due to the diversity of physical phenomena involved, including thermo-mechanical coupling, contact/friction and material failure. The present work outlines the wide range of complex physical phenomena involved in the chip formation in a descriptive manner. In order to improve and understand the process different numerical strategies have been used for simulation. Several of these numerical strategies are reviewed and a short discussion of their relative merits and drawbacks is presented. By means of several examples, where a combined experimental/numerical effort was undertaken, we try to illustrate what numerical techniques, models and pertinent parameters are needed for successful simulations.

Machining simulations is a challenge both with respect to demands on robust numerical methods as well as modelling issues. The paper outlines some of the challenges but also current use of simulations at Sandvik Coromant.

The objective of this paper is to discuss how Knowledge Enabled Engineering, when combined with simulation methods is a development step for product development processes, engineering design methods and evaluation support systems. The paper opens the discussion on how these approaches, i.e. work methods, simulation support and Knowledge Enabled Engineering (KEE) methods affects best practice in engineering design (ED) by adding synthesis support to the already existing analysis support. In the presented work the authors discuss the actual state of industrial applications, with challenges and opportunities, at Volvo Car Corporation, automotive manufacturer, and Volvo Aero Corporation, jet engine component manufacturer, both operating in Sweden.

With an increasing number of and also more complex demands on today’s automobiles the need for fast and accurate simulations to support the Engineering Design (ED) process is getting more important. The demands that are put on the automotive designs are often contradictory i.e. weight against stiffness, and no one optimal set of solutions can be found, rather a trade-off situation. At Volvo Cars Corporation, known all over the world for their safety policy, the advancement to more high strength materials is causing new problems for the engineers. As widely known, a steel material that has been exposed to plastic deformation will suffer hardening in those areas. The work in this paper, exemplified in a deployed demonstrator, show that it is possible to combine forming and crashworthiness simulations in an automated way to make advanced simulation accessible to more people in the product development process. The Knowledge Enabled Engineering (KEE) demonstrator combines forming and crashworthiness simulations for dealing with the constant trade-off in ED.

Residual stresses from the machining process can cause severe failure due to fatigue and stress corrosion. The depth profile of residual stress was measured for high-pressure water-jet assisted machining of Ti-6Al-4V alloy using x-ray diffraction. As comparison, the depth profile of residual stress was also measured for the conventional machined work-piece. The finite element simulation, using the updated Lagrangian formulation was also used to study the dynamic transient process. It was found that the residual stress was a function of machining parameters, such as cutting speed, feed force, depth of cut and particularly the high-pressure jet increases the amount of residual compression stresses in both cutting and feed directions. It is shown that the high-pressure water-jet assisted machining of titanium alloys is beneficial. It reduces shear forces in the secondary cutting zone along the tool/chip interface, reduces the cutting force and introduces compressive residual stress in the finished work-piece.

The commercial success of a new product is influenced by the time to market. Shorter product lead-times are of importance in a competitive market.This can be achieved only if the product development process can be realised in a relatively small time period. New cutting inserts are developed by a time consuming trial and error process guided by empirical knowledge of the mechanical cutting process. One of the state-of-the-art efforts in manufacturing engineering is the finite element simulation of the mechanical cutting process. These computational models would have great value in increasing the understanding of the cutting process and in reducing the number of experiments which traditionally are used for tool design, process selection, machinability evaluation, and chip breakage investigations. This thesis focuses on the development of a finite element model for the cutting process, which can predict chip formation, cutting forces, temperature and pressure distribution on the tool-chip interface and the residual stresses of the work piece. The work is concentrated to handle the large and localised deformations, chip formation and contact and friction. Two basically different modelling approaches have been used for the chip separation, geometrical and physical model. The physical model has been found to be more suitable to simulate the chip formation. The geometrical model is based on the separation of a pre-defined crack path at a certain limit of stresses. In the physical model the chip formation occurs through the plastic deformation of the elements. The excessive element distortion is handled by frequently updating the finite element mesh, using the advance front technique for generation of quadrilateral elements. The adaptive meshing is managed using the error measures based on the stress gradients in the finite element mesh and also the plastic work rate at each element. The automatic control of the mesh quality is managed by using the distortion metric. The implemented combined penalty-barrier contact algorithm has been found to be efficient in conjunction with the adaptive remeshing. The effect of previous cutting on chip formation and the surface residual stresses has been studied. The chip formation is not affected much. There is only a minor influence from the residual stress on the surface from the first cutting on the second pass chip formation. Thus, it is deemed to be sufficient to simulate only the first pass. The influence of the cutting speed and feed on the residual stresses has been computed and verified by the experiments. It is shown that the state of residual stresses in the work piece increases with the cutting speed.