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This paper presents a methodology for practical estimation of the cutting force and cutting power. Providing a complete list of mathematical expressions needed for the calculation, the paper demonstrates their utility for turning operation of two work materials: AISI bearing steel E52100 and aerospace aluminum alloy 2024 T6. The calculated cutting forces are in good agreement with the experimental results. Energy partition in the cutting system and relative impact of the parameters of the machining regime are discussed. For the first time, a simple practical method is available for the calculation of the total cutting power and the cutting force.

To consider the variation of the joint strength on crashworthiness performance of the vehicles, one needs to model the adhesive fracture and/or adhesive bonded joint separation in explicit FE simulations. This paper examines an adhesive material model, MAT169, in LS-DYNA and its capability in modeling of adhesively bonded joints. Initial investigations were conducted on aluminum/epoxy joints including single lap shear, scarf and double cantilever joints. The results show that MAT169 actually is a cohesive interface element implemented in the form of a solid element. MAT169 is computationally efficient and can be used in a production environment. The result of this study is also applicable to adhesively bonded joints with other substrates including composites, steel and hybrid materials.

Laminated steel has been increasingly applied in automotive products for vibration and noise reduction. One of the major challenges the laminated steel poses is how to simulate forming processes and predict formability severity with acceptable correlation in production environment, which is caused by the fact that a thin polymer core possesses mechanical properties with significant difference in comparison with that of steel skins. In this study a cantilever beam test is conducted for investigating flexural behavior of the laminated steel and a finite element modeling technique is proposed for forming simulation of the laminated steel. Two production panels are analyzed for formability prediction and the results are compared with those from the try-out for validation. This procedure demonstrates that the prediction and try-out are in good agreement for both panels.