Many efforts have been focused on the development of Finite Element (FE) machining models due to growing interest in solving practical machining problems in a computational environment in industry. Most of the current models are developed under 2D orthogonal plane strain assumptions, or make use of either arbitrary damage criterion or remeshing techniques for obtaining the chip. A complete understanding of the material removal process together with its effects on the machined parts and wear behaviour of the cutting tools requires accurate 3D computational models to analyze the entire physical phenomenon in materials undergoing large elastic-plastic deformations and large temperature changes as well as high strain rates. This work presents a comparison of 3D machining models developed using commercially available FE softwares ABAQUS/Explicit^© and DEFORM™3D Machining. The work material is chosen as Inconel 718, a difficult-to-cut nickel-based alloy material. Computational results of temperature, strain and stress distributions obtained from the FE models for the effect of cutting speed are presented in comparison with results obtained from experimental tests. In addition, modified material model for Inconel 718 with flow softening is compared with the Johnson-Cook model. The predictions of forces and chip formation are improved with the modified material model.

Surgical procedures that affect the human body's bone structure, often entail cutting, drilling or screwing operations of bone. The post-operative success of these procedures is largely dependent on the degree of damage introduced by the process. In this article, the influence of the rotational velocity, feed per tooth and two drill bit type on workpiece temperatures and cutting forces when drilling bovine cortical bone has been studied. The purpose is to find the optimum cutting conditions that will generate the lower temperatures and cutting forces. The measurement of temperatures has been carried out with an infrared thermography camera, and a piezoelectric dynamometer has been employed to obtain forces. A model has been developed from which heat flow into the drilled bone can be estimated from specific cutting force and the fraction of total heat generated that flows into the bone. This fraction has been shown to depend on the Peclet number for the process, proportional to the drill rotation speed, the feed per cutting edge and the diameter of the drill. By means of the model, some contradictions in the literature as to the effect on bone heating of increasing rotation speeds and feeds per cutting edge have been resolved.

During surgical interventions, bone tissue may be damaged by the achieved high cutting efforts and thermal damage, which should be avoided. In this study, a new surgical drill bit with two types of cutting edges is proposed and tested, reducing tissue damage. Large part of the material is removed by brittle crack propagation, and surface is finished precisely with small uncut chip thickness. Even if temperatures achieved in the bone are not reduced due to rubbing effects, lower cutting force and processing energy, and better surface roughness are obtained with the proposed tool compared to the conventional drill bit.

Air jet impingement systems have proven to be a very efficient way of heat transfer in single phase flows, which has allowed them to be applied in several industries. However, the complexity of the physical phenomena that take place in the cooling or heating processes makes the task of designing and sizing a system of this type very difficult. The objective of this work is to develop a methodology for the optimization of the impingement plate for electronic components cooling systems. The component chosen to exemplify this work is an insulated gate bipolar transistor (IGBT) such as those employed in photovoltaic inverters. The proposed methodology is divided into the thermo-hydraulic calculation process and the optimization of the system. This optimization is carried out using a multi-objective particle swarm optimization (PSO) algorithm that seeks the best compromise between two variables: Component temperature and manufacturing time of the impingement plate. The result is a calculation tool that can quickly find the solution that meets the requirements of the designer without the need to evaluate all possible solutions.