Finite element analysis of the influence of tool edge radius on size effect in orthogonal micro-cutting process

In this paper, a series of simulation works by finite element method for predicting the temperature and the plastic strain distributions in micro cutting process with the tool edge radius considered were conducted. The workpiece is Aluminum alloy 7050-T7451 and its flow stress is taken as a function of strain, strain rate and temperature in order to reflect realistic behavior in machining process. From the simulation works, a lot of information on the micro-machining process can be obtained, such as cutting force, cutting temperature, distributions of temperature and plastic strain, etc. In addition, explanations for the observed trends are also given.

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Finite Element Analysis of Cutting Force and Burr Formation in Micro-Cutting of Titanium Alloy Considering Tool Edge Radius

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.426.235 ◽

2012 ◽

Vol 426 ◽

pp. 235-238 ◽

Cited By ~ 1

Author(s):

Da Peng Dong ◽

Xiao Hu Zheng ◽

Ming Chen ◽

Qing Long An

Keyword(s):

Cutting Force ◽

Simulation Modeling ◽

Burr Formation ◽

Element Analysis ◽

Micro Cutting ◽

Tool Edge Radius ◽

Cutting Energy ◽

Burr Size ◽

Edge Radius ◽

Tool Edge

In recent years, with the development of machinery industry, micro-cutting technologies have been gradually moving into engineering realization. The paper carries out a series of works on simulation modeling of micro-cutting of Ti-5Al-5V-5Mo-3Cr considering tool edge radius. Unlike conventional cutting, in micro-cutting the effect of tool edge radius which has a marked impact on cutting force, specific cutting energy, burr formation and burr size can no longer be neglected.

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Finite element analysis of the grain size effect on diffusion in polycrystalline materials

Computational Materials Science ◽

10.1016/j.commatsci.2014.07.026 ◽

2014 ◽

Vol 95 ◽

pp. 187-191 ◽

Cited By ~ 14

Author(s):

V. Lacaille ◽

C. Morel ◽

E. Feulvarch ◽

G. Kermouche ◽

J.-M. Bergheau

Keyword(s):

Finite Element Analysis ◽

Grain Size ◽

Finite Element ◽

Size Effect ◽

Polycrystalline Materials ◽

Grain Size Effect ◽

Element Analysis

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Simulation of Meso-Scale Machining of AISI1045 Based on Multiphase Model

Materials Science Forum ◽

10.4028/www.scientific.net/msf.836-837.374 ◽

2016 ◽

Vol 836-837 ◽

pp. 374-380

Author(s):

Teng Yi Shang ◽

Li Jing Xie ◽

Xiao Lei Chen ◽

Yu Qin ◽

Tie Fu

Keyword(s):

Cutting Force ◽

Cutting Process ◽

Multiphase Model ◽

Tool Edge Radius ◽

Edge Radius ◽

Tool Edge ◽

Cutting Insert ◽

Multiphase Models ◽

Hot Rolled ◽

Meso Scale

In the meso-scale machining, feed rate, grain size and tool edge radius are in the same order of magnitude, and cutting process is often carried out in the grain interior and grain boundary. In this paper the meso-cutting process of hot-rolled AISI1045 steel is studied and its metallographic microstructure is analyzed for the establishment of multiphase models which incorporate the effect of ferrite and pearlite grains. In order to discover the applicability of multiphase models to the simulation of meso-cutting, three contrast simulation models including multiphase model with rounded-edge cutting insert (model I), multiphase model with sharp edge cutting insert (model II) and equivalent homogeneous material model with rounded-edge cutting insert (model III) are built up for the meso-orthogonal cutting processes of hot-rolled AISI1045. By comparison with the experiments in terms of chip morphology, cutting force and specific cutting force, the most suitable model is identified. Then the stress distiribution is analyzed. And it is found that multiphase model with tool edge radius can give a more accurate prediction of the global variables and reveal more about these important local variables distribution.

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Chatter Stability Prediction of Cutting Process With Process Damping Utilizing Finite Element Analysis

JSME 2020 Conference on Leading Edge Manufacturing/Materials and Processing ◽

10.1115/lemp2020-8556 ◽

2020 ◽

Author(s):

Norikazu Suzuki ◽

Tomoki Nakanomiya ◽

Eiji Shamoto

Keyword(s):

Finite Element Analysis ◽

Finite Element ◽

Vibration Amplitude ◽

Cutting Process ◽

Force Model ◽

Chatter Stability ◽

Chatter Vibration ◽

Damping Force ◽

Element Analysis ◽

Process Damping

Abstract This paper presents a new approach to predict chatter stability in cutting considering process damping. Traditional chatter stability analysis methods enable to predict stable or unstable conditions. Under unstable conditions, the chatter vibration can increase theoretically infinitely. However, chatter vibration is damped at a certain amplitude in real process due to process damping, i.e., the cutting process is stabilized by means of tool flank face contact to the machined surface. In order to consider the influence of the process damping, a simple process damping force model is introduced. The process damping force is assumed to be proportional to the structural displacement. The process damping coefficient is a function of the vibration amplitude and the wavelength. In order to identify the coefficients, a series of finite element analysis is conducted in the present study. Identified coefficients are introduced into the conventional zero-order-solution in frequency domain. The proposed model calculates chatter stability limit assuming process damping with finite amplitude. Hence, this analysis enables to estimate the amplitude-dependent quasi-stable conditions. Analytical results for thee face turning operation demonstrated influence of process damping effect on resultant vibration amplitude quantitatively.

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