Finite element analysis of the orthogonal metal cutting process

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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Research of Data Processing Methods for Metal Cutting Finite Element Analysis Results

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.192.14 ◽

2012 ◽

Vol 192 ◽

pp. 14-18

Author(s):

Ming Cong ◽

Jian Song

Keyword(s):

Finite Element Analysis ◽

Finite Element ◽

Cutting Force ◽

Metal Cutting ◽

Element Analysis ◽

Noise Data ◽

Force Data ◽

Bad Data ◽

Deform 3D ◽

Data Processing Methods

In this paper, the turning process of 45# steel was simulated and analyzed based on the metal cutting finite element analysis software DEFORM-3D. The analysis result of cutting force was gained. However, due to some reasons of the software itself, there is noise data in analysis results. Thus, it’s needed to filter the data to extract useful information. The selected short-duration and steady-state cutting force data was processed with the use of six-sigma rule through mathematical statistics analysis. As a result, some bad data were rejected. Noise data was filtered out via wavelet analysis and the processed function curve of cutting force that changes with time during the whole cutting course was gained.

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Finite element analysis of temperature rise in metal cutting processes

Applied Thermal Engineering ◽

10.1016/j.applthermaleng.2005.01.006 ◽

2005 ◽

Vol 25 (14-15) ◽

pp. 2152-2168 ◽

Cited By ~ 50

Author(s):

Pradip Majumdar ◽

R. Jayaramachandran ◽

S. Ganesan

Keyword(s):

Finite Element Analysis ◽

Finite Element ◽

Temperature Rise ◽

Metal Cutting ◽

Element Analysis ◽

Cutting Processes

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Research on Simulation of Cutting Process Based on the Finite Element Analysis Method

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.631-632.686 ◽

2013 ◽

Vol 631-632 ◽

pp. 686-690

Author(s):

Yi Li Shen

Keyword(s):

Finite Element Analysis ◽

Finite Element ◽

New Technologies ◽

Cutting Process ◽

Analysis Method ◽

Organizational Models ◽

Element Analysis ◽

Finite Element Analysis Method ◽

The Finite Element Analysis ◽

Cad Cam

With the rapid penetration of information technology in various fields, CAD/CAM/CAE technology has been widely used to fundamentally change the traditional design, production, organizational models, it also has a very important significance to promote the technological transformation of existing enterprises, bring the whole structural change of the night, develop the new technologies and the promotion of economic growth. The paper uses the blades of steam turbine as an example, combined with the finite element analysis method to study the whole cutting process, the whole process was simulated and the results of error were had analysis and optimization.

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