A comprehensive review of finite element modeling of orthogonal machining process: chip formation and surface integrity predictions

2018 ◽  
Vol 96 (9-12) ◽  
pp. 3747-3791 ◽  
Author(s):  
Morteza Sadeghifar ◽  
Ramin Sedaghati ◽  
Walid Jomaa ◽  
Victor Songmene
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Surface Integrity ◽  
Chip Formation ◽  
Machining Process ◽  
Comprehensive Review ◽  
Element Modeling ◽  
Orthogonal Machining

Investigation on Chip Formation during Machining Using Finite Element Modeling

2012 ◽  
Vol 505 ◽  
pp. 31-36 ◽  
Author(s):  
Moaz H. Ali ◽  
Basim A. Khidhir ◽  
Bashir Mohamed ◽  
A.A. Oshkour
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Finite Element Modeling ◽  
Chip Formation ◽  
Cutting Tool ◽  
Chip Morphology ◽  
Machining Process ◽  
Element Modeling ◽  
Segmented Chip ◽  
Cutting Speeds

Titanium alloys are desirable materials for aerospace industry because of their excellent combination of high specific strength, lightweight, fracture resistant characteristics, and general corrosion resistance. Therefore, the chip morphology is very important in the study of machinability of metals as well as the study of cutting tool wear. The chips are generally classified into four groups: continuous chips, chips with built-up-edges (BUE), discontinuous chips and serrated chips. . The chip morphology and segmentation play a predominant role in determining machinability and tool wear during the machining process. The mechanics of segmented chip formation during orthogonal cutting of titanium alloy Ti–6Al–4V are studied in detail with the aid of high-speed imaging of the chip formation zone. The finite element model of chip formation of Ti–6Al–4V is suggested as a discontinuous type chip at lower cutting speeds developing into a continuous, but segmented, chip at higher cutting speeds. The prediction by using finite-element modeling method and simulation process in machining while create chips formation can contribute in reducing the cost of manufacturing in terms of prolongs the cutting tool life and machining time saving.

scholarly journals FINITE ELEMENT MODELING OF THE ORTHOGONAL MACHINING OF PARTICLE REINFORCED ALUMINUM BASED METAL MATRIX COMPOSITES

2014 ◽  
Vol 2014 (04) ◽  
pp. 511-515 ◽  
Author(s):  
Usama Umer ◽  
Mohammad Ashfaq ◽  
Jaber Abu Qudeiri ◽  
Hussein Mohammed ◽  
Abdalmonaem Hussein ◽  
...  
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Metal Matrix Composites ◽  
Metal Matrix ◽  
Matrix Composites ◽  
Element Modeling ◽  
Orthogonal Machining

Finite element modeling and analysis of powder mixed electric discharge machining process for temperature distribution and volume removal considering multiple craters

2014 ◽  
Vol 05 (03) ◽  
pp. 1450009 ◽  
Author(s):  
Hardeep Singh ◽  
Anirban Bhattacharya ◽  
Ajay Batish
Keyword(s):  
Finite Element ◽  
Temperature Distribution ◽  
Finite Element Modeling ◽  
Electric Discharge ◽  
Material Removal ◽  
Peak Temperature ◽  
Machining Process ◽  
Electric Discharge Machining ◽  
Element Modeling ◽  
Pulse On Time

Powder mixed electric discharge machining (PMEDM) is one of the modern developments in electric discharge machining (EDM) process. In the present work, finite element modeling has been carried out considering randomly oriented multiple sparks during PMEDM. Transient thermal analysis is done to obtain temperature distribution, volume removal, and proportion of volume removed by melting and evaporation at different current, pulse on time and fraction of heat that enters to work piece. Gradually growing spark behavior and Gaussian distribution of heat source is used to simulate multiple craters. Temperature distribution along radial direction shows peak temperature at center of spark and thereafter a gradual decrease with increase in radial distance. Along depth direction temperature sharply decreases that forms wider craters with shallow depth in PMEDM. Peak temperature and volume removal increases with current more rapidly. Volume removal by melting is much higher than evaporation at lower current settings and with higher current almost equal amount of material is removed by melting and evaporation thus reducing the re-solidification of melted material. Current plays a significant role behind the contribution of material removal by evaporation followed by fraction of heat. Increase in pulse on duration increases the total volume of material removal however does not significantly increase the proportion of volume removal by vaporization.

L16 Orthogonal Array-Based Three-Dimensional Finite Element Modeling for Cutting Force and Chip Formation Analysis During Dry Machining of Ti–6Al–4V

2020 ◽  
pp. 1-12
Author(s):  
Raviraj Shetty ◽  
Sanjeev Kumar ◽  
Ravindra Mallagi ◽  
Laxmikanth Keni
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Cutting Force ◽  
Chip Formation ◽  
Orthogonal Array ◽  
Three Dimensional ◽  
Cutting Conditions ◽  
Element Modeling ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element

The outstanding characteristics of titanium alloy (Ti–6Al–4V) have made this material applicable in aerospace and medical components. However, due to its poor machinability characteristics, researchers are forced to understand the machinability behavior of Ti–6Al–4V. In this paper, [Formula: see text] orthogonal array-based three-dimensional finite element modeling for the cutting force and chip formation analysis during the machining of Ti–6Al–4V using cubic boron nitride tool in dry turning environment has been investigated. The finite element simulation was performed using ANSYS Workbench, version 19.0. Cutting force and chip formation were investigated using the results obtained from [Formula: see text] orthogonal array-based three-dimensional finite element modeling. This research would help to identify the optimum cutting conditions and minimize the cutting force followed by analyzing the types of chips formed during machining under the selected set of cutting conditions.

Finite Element Modeling of Cutting Force and Chip Formation During Thermally Assisted Machining of Ti6Al4V Alloy

2013 ◽  
Vol 135 (6) ◽  
Author(s):  
Yao Xi ◽  
Michael Bermingham ◽  
Gui Wang ◽  
Matthew Dargusch
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Cutting Force ◽  
Formation Process ◽  
Chip Formation ◽  
Cutting Forces ◽  
Experimental Results ◽  
Strongly Correlated ◽  
Element Modeling ◽  
Simulation Results

The improvement in machinability during thermally assisted turning of the Ti-6Al-4V alloy has been investigated using finite element modeling. A 2D thermally assisted turning model was developed and validated by comparing the simulation results with experimental results. The effect of workpiece temperature on the cutting force and chip formation process was examined. The predicted cutting forces and chip morphologies from the simulation strongly correlated with the experimental results. It was observed from the simulation that the chip forms after the coalescence of two deformed regions in the shear band and that the cyclic cutting forces are strongly related to this chip formation process.

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