Finite element analysis of orthogonal cutting of cellular metals: influence of cutting conditions on chip formation and surface damage

2021 ◽  
Vol 113 (5-6) ◽  
pp. 1267-1280
Author(s):  
Rafael Guerra-Silva ◽  
Uwe Teicher ◽  
Steffen Ihlenfeldt ◽  
Arístides González-Zamora
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Chip Formation ◽  
Orthogonal Cutting ◽  
Surface Damage ◽  
Cutting Conditions ◽  
Element Analysis ◽  
Cellular Metals ◽  
On Chip

Finite Element Analysis of Chip Formation in Micro-Milling Operation

2020 ◽  
pp. 202-213
Author(s):  
Leo Kumar S. P. ◽  
Avinash D.
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Chip Formation ◽  
End Milling ◽  
Numerical Technique ◽  
Tool Material ◽  
Micro Milling ◽  
Element Analysis ◽  
Milling Operation ◽  
On Chip

Finite element analysis (FEA) is a numerical technique in which product behavior under various loading conditions is predicted for ease of manufacturing. Due to its flexibility, its receiving research attention across domain discipline. This chapter aims to provide numerical investigation on chip formation in micro-end milling of Ti-6Al-4V alloy. It is widely used for medical applications. The chip formation process is simulated by a 3D model of flat end mill cutter with an edge radius of 5 μm. Tungsten carbide is used as a tool material. ABACUS-based FEA package is used to simulate the chip formation in micro-milling operation. Appropriate input parameters are chosen from the published literature and industrial standards. 3-D orthogonal machining model is developed under symmetric proposition and assumptions in order to reveal the chip formation mechanism. It is inferred that the developed finite element model clearly shows stress development in the cutting region at the initial stage is higher. It reduces further due to tool wear along the cutting zone.

scholarly journals Surface Micromachined Silicon Carbide Accelerometers for Gas Turbine Applications

1999 ◽  
Author(s):  
Russell G. DeAnna
Keyword(s):  
Finite Element Analysis ◽  
Silicon Carbide ◽  
Finite Element ◽  
Mechanical Design ◽  
Sacrificial Layer ◽  
Shape Change ◽  
Chemical Vapor ◽  
Element Analysis ◽  
Centripetal Acceleration ◽  
On Chip

A finite-element analysis of possible silicon carbide (SiC), folded-beam, lateral-resonating accelerometers is presented. Results include stiffness coefficients, acceleration sensitivities, resonant frequency versus temperature, and proof-mass displacements due to centripetal acceleration of a blade-mounted sensor. The surface micromachined devices, which are similar to the Analog Devices® Inc., (Norwood, MA) air-bag crash detector, are etched from 2-μm thick, 3C-SiC films grown at 1600 K using atmospheric pressure chemical vapor deposition (APCVD). The substrate is a 500 μm-thick, (100) silicon wafer. Polysilicon or silicon dioxide is used as a sacrificial layer. The finite-element analysis includes temperature-dependent properties, shape change due to volume expansion, and thermal stress caused by differential thermal expansion of the materials. The finite-element results are compared to experimental results for a SiC device of similar, but not identical, geometry. Along with changes in mechanical design, blade-mounted sensors would require on-chip circuitry to cancel displacements due to centripetal acceleration and improve sensitivity and bandwidth. These findings may result in better accelerometer designs for this application.

scholarly journals Finite Element Analysis on Discontinuous Chip Formation.

1993 ◽  
Vol 59 (5) ◽  
pp. 821-826 ◽  
Author(s):  
Toshiyuki OBIKAWA ◽  
Katsuyuki TAGUCHI ◽  
Hiroyuki SASAHARA ◽  
Takahiro SHIRAKASHI ◽  
Eiji USUI
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Chip Formation ◽  
Element Analysis

scholarly journals Comparison between finite element analysis and rheological models for chip formation

2020 ◽  
Vol 23 (2) ◽  
pp. 255-268
Author(s):  
Olga Liivapuu ◽  
Jüri Olt ◽  
Tanel Tärgla
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Numerical Methods ◽  
Chip Formation ◽  
Cutting Parameters ◽  
Finite Element Models ◽  
Empirical Methods ◽  
Element Analysis ◽  
Rheological Models ◽  
Selection Of

In the process of cutting, often the selection of cutting parameters is done considering empirical methods. This approach is more expensive and does not usually lead to the best solutions. Numerical methods for simulating the chip formation have been under development over the last thirty years. The aim of the present research is to compare models based on rheological properties of metals with 2D Finite Element Models of chip formation process.

scholarly journals Finite Element Analysis Of Influence Of Flank Wear Evolution On Forces In Orthogonal Cutting Of 42CrMo4 Steel

2017 ◽  
Vol 37 (1) ◽  
pp. 58-64
Author(s):  
Marek Madajewski ◽  
Zbigniew Nowakowski
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Cutting Force ◽  
Flank Wear ◽  
Orthogonal Cutting ◽  
Element Model ◽  
Element Analysis ◽  
Force Magnitude ◽  
Feed Force ◽  
42Crmo4 Steel

Abstract This paper presents analysis of flank wear influence on forces in orthogonal turning of 42CrMo4 steel and evaluates capacity of finite element model to provide such force values. Data about magnitude of feed and cutting force were obtained from measurements with force tensiometer in experimental test as well as from finite element analysis of chip formation process in ABAQUS/Explicit software. For studies an insert with complex rake face was selected and flank wear was simulated by grinding operation on its flank face. The aim of grinding inset surface was to obtain even flat wear along cutting edge, which after the measurement could be modeled with CAD program and applied in FE analysis for selected range of wear width. By comparing both sets of force values as function of flank wear in given cutting conditions FEA model was validated and it was established that it can be applied to analyze other physical aspects of machining. Force analysis found that progression of wear causes increase in cutting force magnitude and steep boost to feed force magnitude. Analysis of Fc/Ff force ratio revealed that flank wear has significant impact on resultant force in orthogonal cutting and magnitude of this force components in cutting and feed direction. Surge in force values can result in transfer of substantial loads to machine-tool interface.

Sign in / Sign up

Export Citation Format

Share Document