scholarly journals Numerical simulation of two tool turning process

2018 ◽  
Vol 192 ◽  
pp. 01001 ◽  
Author(s):  
Kalidasan Rathinam ◽  
Sandeep Kumar
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Cutting Tool ◽  
Cutting Temperature ◽  
Element Model ◽  
Separation Distance ◽  
Recrystallization Temperature ◽  
Turning Process ◽  
Element Analysis ◽  
Feed Force

Double tool turning process is used to improve productivity. A 2D finite element model was developed using commercially available finite element analysis software Abaqus 6.13. The workpiece and the cutting tool materials are modelled as elasto-plastic and elastic material respectively. Johnson-Cook damage criterion was used for chip separation. The friction between the cutting tool and the workpiece is modelled based on penalty contact approach. The coefficient of friction between the chip and the first and second cutting tool was taken as 0.8 and 0.6 respectively. In this numerical investigation the effect tool separation distance over the cutting force, feed force and cutting temperature were studied. Three different tool separation distances were considered. The simulation result shows that cutting force and feed force of the front cutting tool and the rear cutting tool do not change appreciably with the variation of the tool separation distance. It was revealed that the temperature rise of the work material due to machining by two cutting tool is well below the recrystallization temperature. Hence the forces on front and rear cutting tool remain same for various tool separation distances. It was also observed that the cutting temperatures remained unchanged for the various tool separation distances.

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.

Finite Element Analysis of Tool Stresses, Temperature and Prediction of Cutting Forces in Turning Process

2017 ◽  
Vol 261 ◽  
pp. 354-361 ◽  
Author(s):  
Martin Necpal ◽  
Peter Pokorný ◽  
Marcel Kuruc
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Element Model ◽  
Turning Process ◽  
Element Analysis ◽  
Tool Stresses ◽  
Chip Separation ◽  
Carbide Insert

The paper presents the simulation model of turning the process of C45 non-alloy steel with a tool made of carbide insert. A 3D final element model used a lagrangian incremental type and re-meshing chip separation criterion was experimentally verified by measure cutting forces using piezoelectric dynamometer. In addition, stresses and temperature in the tooltip were predicted and examine. This work could investigate failure the tooltip, which would be great interest to predict wear and damage of cutting tool.

The Numerical Simulation of the Aluminum Alloy Processing

2011 ◽  
Vol 188 ◽  
pp. 590-595
Author(s):  
B.J. Xiao ◽  
Cheng Yong Wang ◽  
Ying Ning Hu ◽  
Yue Xian Song
Keyword(s):  
Finite Element ◽  
Aluminum Alloy ◽  
Friction Coefficient ◽  
Cutting Force ◽  
Cutting Temperature ◽  
Element Model ◽  
Adaptive Meshing ◽  
Surface Residual Stress ◽  
Element Analysis ◽  
The Impact

A two-dimensional orthogonal thermal-mechanical finite element model by Deform2D finite element analysis software is established in the article. By the adaptive meshing technique, not only cutting process but also the effect on the process of aluminum alloy Al6061-T6 processing as friction coefficient changing is simulated. The simulation shows that the friction coefficient has significant effect on the cutting temperature and cutting force, and the effect is nonlinear. With the increasing of the friction coefficient, the cutting temperature and cutting force will both increase. The impact the friction coefficient has on the surface residual stress is much smaller than the impact on the cutting temperature and cutting force.

Temperature Field Numerical Analysis of Machining Process Based on the Finite Element Analysis

2014 ◽  
Vol 621 ◽  
pp. 611-616 ◽  
Author(s):  
Yan Juan Hu ◽  
Yao Wang ◽  
Zhan Li Wang
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Element Model ◽  
Machining Process ◽  
Element Analysis ◽  
Mechanical Coupling

In order to study the temperature field distribution in the process of machining, the finite element theory was used to establish the orthogonal cutting finite element model, and the key technologies were discussed simultaneously. By using ABAQUS software for cutting AISI1045 steel temperature field of numerical simulation, the conclusion about changing rule of cutting temperature field can be gotten. The results show that this method can efficiently simulate the distribution of temperature field of the workpiece, cutter and scraps, which is effected by thermo-mechanical coupling in metal work process. It provides the theory evidence for the intensive study of metal-cutting principle, optimizing cutting parameters and improving processing technic and so on.

Modeling and Simulation of High Speed Intermittent Cutting Based on the Finite Element Method

2013 ◽  
Vol 683 ◽  
pp. 556-559
Author(s):  
Bin Bin Jiao ◽  
Fu Sheng Yu ◽  
Yun Jiang Li ◽  
Rong Lu Zhang ◽  
Gui Lin Du ◽  
...  
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Stress Field ◽  
Cutting Force ◽  
High Speed ◽  
Element Model ◽  
Periodic Variation ◽  
Element Analysis ◽  
Intermittent Cutting ◽  
Element Method

In order to study the distribution of the stress field in the high-speed intermittent cutting process, finite element model of high-speed intermittent cutting is established. Exponential material model of the constitutive equation and adaptive grid technology are applied in the finite element analysis software AdvantEdge. The material processing is simulated under certain cutting conditions with FEM ( Finite Element Method ) and the distribution of cutting force, stress field, and temperature field are received. A periodic variation to the cutting force and temperature is showed in the simulation of high-speed intermittent cutting. Highest value of the milling temperature appears in front contacting area of the knife -the chip.and maximum stress occurs at the tip of tool or the vicinity of the main cutting edge. The analysis of stress and strain fields in-depth is of great significance to improve tool design and durability of tool.

Turning Process Modeling and Cutting Force Investigation Based on Finite Element Analysis and Cutting Experiments

2011 ◽  
Vol 314-316 ◽  
pp. 900-903
Author(s):  
Yan Cao ◽  
Hua Chen ◽  
Hai Xia Zhao
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Cutting Parameters ◽  
Turning Process ◽  
Rigid Plastic ◽  
Element Analysis ◽  
Fea Model ◽  
Cutting Experiments

On the basis of metal cutting and rigid-plastic finite element theories, taking cutting force in turning process as the research object, a FEA model for turning process using a MDT cutter on a centre lathe CA6140 is constructed to simulate its metal cutting process. Using Deform 3D, cutting forces are calculated according to different cutting parameters. The influences of the cutting parameters on the cutting forces are investigated. In order to validate the FEA model, cutting experiments are conducted. Comparison between simulated cutting forces and experimental forces shows similar trends and reasonable agreement.

The Coupling Thermal and Mechanical Analysis of Machining Aluminum Alloy Work-Piece Based on FEM

2013 ◽  
Vol 468 ◽  
pp. 20-23
Author(s):  
Mu Lan Wang ◽  
Jun Ming Hou ◽  
Bao Sheng Wang
Keyword(s):  
Finite Element ◽  
Aluminum Alloy ◽  
Cutting Force ◽  
Digital Simulation ◽  
Three Dimensional ◽  
Cutting Temperature ◽  
Element Model ◽  
Depth Of Cut ◽  
Work Piece ◽  
Cutting Model

The Cutting force and cutting temperature are the important factors which can affect the quality and accuracy of the aluminum alloy work-pieces. Based on the theoretical analysis of the cutting force and cutting temperature, the three-dimensional Finite Element Model (FEM) with the overall tool is established. The corresponding results of the digital simulation were researched, and the cutting force and cutting temperature were analyzed. The cutting temperature and cutting force changes were compared by altering the axial depth of cut and the feed rate. Keywords: Oblique cutting model, Finite Element Method (FEM), Cutting temperature, Cutting force, Aluminum alloy work-piece

Finite Element Analysis of Temperature Field in Vibration Milling

2016 ◽  
Vol 693 ◽  
pp. 1030-1037
Author(s):  
Xue Hui Shen ◽  
Ming Yu Wang
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Ultrasonic Vibration ◽  
Cutting Temperature ◽  
Element Model ◽  
Milling Process ◽  
Element Analysis ◽  
Fem Method ◽  
Dimensional Finite Element ◽  
Vibration Milling

The purpose of this paper is to investigate the variation of temperature field of ultrasonic vibration assisted milling compared with that of conventional milling by FEM method. An equivalent two-dimensional finite element model was built to simplify the complexity of calculation. As results, the temperature field distribution, the variation of tool tip temperature and the change of heat generation rate in ultrasonic vibration assisted milling were analyzed compared with that in conventional milling process. According to analytical results, the application of ultrasonic vibration in milling process can significantly improve the distribution of cutting temperature, and reduce the impacts of thermal deformation and various thermal effects to cutting process.

Ultrasonic-Vibration Hard Cutting Force Analysis with the Finite Element Method

2010 ◽  
Vol 455 ◽  
pp. 360-364 ◽  
Author(s):  
Jing Lin Tong ◽  
Yan Yan Yan ◽  
Bo Zhao
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Element Model ◽  
Advanced Technology ◽  
Hard Cutting

Ultrasonic-vibration hard cutting (UVHC) is a advanced technology, where high- frequency vibration is superimposed on the movement of the cutting tool. Compared to conventional turning (CT), this technique allows significant improvements in processing hard-to-cut materials, by producing a noticeable decrease in cutting forces and a superior surface finish. The paper presents a finite-element model of both CT and UVHC. Stresses produced in workpiece and cutting forces acting on the cutting tool in UVHC are studied, and the influence of cutting parameters, such as cutting speed and cutting depth on cutting force are investigated.

Finite Element Analysis of Deformation of the Multipoint Flexible Clamped Thin-Wall Component during Machining

2012 ◽  
Vol 542-543 ◽  
pp. 519-522
Author(s):  
Guo Qiang Cao ◽  
Yi Yu Sun
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Vertical Direction ◽  
Element Model ◽  
Numerical Control ◽  
Skin Thickness ◽  
Thin Wall ◽  
Element Analysis ◽  
Maximum Deformation ◽  
The Finite Element Model

A study on deformation of multipoint flexible clamped thin-wall components during numerical control drilling in vertical direction downward is presented. The finite element model of multipoint flexible clamped thin-wall component during machining is established with program ANSYS, and a static analysis of deformation of the model is conducted. The laws of maximum deformation under different skin thickness, under different cutting force and on the 3 special machining paths in the cut area are obtained. The results show that the maximum deformation is linear with cutting force and exponential with skin thickness, and the function curves of the maximum deformation on the 3 special machining paths are all different, the function curve 2 is the composite superposition of the function curve 1 and the function curve 3.

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