2D-FEM SIMULATION OF THE ORTHOGONAL HIGH SPEED CUTTING PROCESS

2001 ◽  
Vol 5 (3) ◽  
pp. 323-340 ◽  
Author(s):  
F. Klocke ◽  
H.-W. Raedt ◽  
S. Hoppe
Keyword(s):  
High Speed ◽  
Fem Simulation ◽  
Cutting Process ◽  
High Speed Cutting

Finite Element Analysis of Cutting Forces in High Speed Machining

2006 ◽  
Vol 532-533 ◽  
pp. 753-756 ◽  
Author(s):  
Jun Zhao ◽  
Xing Ai ◽  
Zuo Li Li
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Cutting Forces ◽  
High Speed ◽  
Fem Simulation ◽  
Chip Thickness ◽  
Cutting Conditions ◽  
Cutting Process ◽  
Undeformed Chip Thickness ◽  
High Speed Cutting

The Finite Element Method (FEM) has proven to be an effective technique to investigate cutting process so as to improve cutting tool design and select optimum cutting conditions. The present work focuses on the FEM simulation of cutting forces in high speed cutting by using an orthogonal cutting model with variant undeformed chip thickness under plane-strain condition to mimic intermittent cutting process such as milling. High speed cutting of 45%C steel using uncoated carbide tools are simulated as the application of the proposed model. The updated Lagrangian formulation is adopted in the dynamic FEM simulation in which the normalized Cockroft and Latham damage criterion is used as the ductile fracture criterion. The simulation results of cutting force components under different cutting conditions show that both the thrust cutting force and the tangential cutting force increase with the increase in undeformed chip thickness or feed rate, whereas decrease with the increase in cutting speed. Some important aspects of modeling the high speed cutting are discussed as well to expect the future work in FEM simulation.

Identification of Flow Stress Applicable for FEM Simulation of Orthogonal Cutting Process

2014 ◽  
Vol 625 ◽  
pp. 378-383 ◽  
Author(s):  
Norfariza Wahab ◽  
Yumi Inatsugu ◽  
Satoshi Kubota ◽  
Soo Young Kim ◽  
Hiroyuki Sasahara
Keyword(s):  
Flow Stress ◽  
Strain Rate ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Fem Simulation ◽  
Material Model ◽  
Cutting Process ◽  
Machining Parameters ◽  
High Speed Cutting ◽  
Cutting Test

Nowadays, numerical simulation technique is very popular to estimate and predict the machining parameters such as cutting forces, stresses distribution, temperature and tool wear. The objective of this study is to determine the 0.45%C steel (JIS S45C) flow stress value under high strain rate and temperature. The Johnson and Cook (JC) material model is used as a constitutive equation to describe the high speed cutting process. Compression test and orthogonal cutting test were carried out in order to obtain the required parameters in JC model. Inverse calculation method was used to determine the strain rate and temperature dependency parameter based on several cutting conditions. As a result, validity of verification of method was completed and the flow stress of S45C had been evaluated.

The Forming Mechanism of Surface Defects on Machined Surface in High-Speed Cutting of SiCp/Al Composites

2013 ◽  
Vol 579-580 ◽  
pp. 171-176
Author(s):  
Yang Jun Wang ◽  
Ming Qiang Pan ◽  
Tao Chen ◽  
Li Guo Chen
Keyword(s):  
High Speed ◽  
Surface Defects ◽  
Fem Simulation ◽  
Cutting Parameters ◽  
Cutting Process ◽  
Machined Surface ◽  
High Speed Cutting ◽  
Forming Mechanism ◽  
Simulation And Experiment ◽  
Method Model

For investigating the machined surface defects in high-speed cutting of SiCp/Al composites. The simulation and experiment of high-speed cutting process is done. The simulation of high-speed cutting process using the Cowper-Symonds model is established to explore the forming mechanism of the machined surface defects. The results show that the machined surface defects include small pit, big pit, groove and the raised particle. The experiment which uses the same cutting parameters with the simulation of FEM (Finite Element Method) model is carried out to verify the results of FEM simulation. The results indicate that the forming mechanism of machined surface defects prove to be true.

Vibrations in High Speed Boring Process of Bioengineering Polymers

2016 ◽  
Vol 856 ◽  
pp. 125-128
Author(s):  
Athanasios G. Mamalis ◽  
G. Tokhtar ◽  
Sergiy Lavrynenko
Keyword(s):  
High Speed ◽  
Cutting Process ◽  
Machining Process ◽  
Effective Alternative ◽  
High Quality ◽  
High Speed Cutting ◽  
Operation Control

At the present time the polymers are reliable and effective alternative to more traditional materials for many applications especially for bioengineering. Achievement of high quality biopolymeric components demands particular conditions for the machining process and its control. This report is devoted to method for operation control of the high speed cutting process by measurement of vibrating acceleration.

Finite Element Simulation on High Speed Cutting of Hardened 45 Steel Based on ABAQUS

2013 ◽  
Vol 579-580 ◽  
pp. 202-207
Author(s):  
Guo He Li ◽  
Hou Jun Qi ◽  
Bing Yan
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Finite Element Simulation ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Cutting Process ◽  
High Speed Cutting ◽  
Geometry Model ◽  
Element Simulation

For the high speed cutting process of hardened 45 steel (45HRC), a finite element simulation of cutting deformation, cutting force and cutting temperature is finished with the large general finite element software ABAQUS. Through the building of geometry model, material model and heat conduction model, also the determination of boundary conditions, separation rule and friction condition, a thermal mechanical coupling finite element model of high speed cutting for hardened 45 steel is built. The serrated chip, cutting force and cutting temperature can be predicted. The comparison of experiment and simulation shows the validity of the model. The influence of cutting parameters on cutting process is investigated by the simulation under different cutting depthes and rake angles. The results show that as the increase of rake angle, the segment degree, cutting force and cutting temperature decrease. But the segment degree, also the cutting force and cutting temperature increase with the increase of cutting depth. This study is useful for the selection of cutting parameters of hardened steel.

Simulation of High-Speed Cutting Process Based on ABAQUS

2011 ◽  
Vol 230-232 ◽  
pp. 1221-1225 ◽  
Author(s):  
Xia Yu ◽  
Xu Yao Sun ◽  
Dan Ke Wei
Keyword(s):  
High Speed ◽  
Chip Morphology ◽  
Material Model ◽  
Rake Angle ◽  
Cutting Process ◽  
Fe Model ◽  
High Speed Cutting ◽  
Line Technology ◽  
Chip Separation ◽  
The Impact

Using the separation line technology, established a FE model of two-dimensional cutting process for AISI4340 steel and discussed some basic theory and pivotal questions associated with the simulation of cutting process including the Johnson-Cook material model, the contact model between tool and chip, criteria of chip separation and so on. In order to study the impact of tool rake angle on the chip morphology and the cutting forces, the high-speed cutting process for AISI 4340 steel was simulated based on ABAQUS software. Also, analyzed the influence of mesh azimuth on the chip morphology and its temperature distribution.

An Integral Method to Determine Workpiece Flow Stress and Friction Characteristics in Metal Cutting

2015 ◽  
Vol 9 (6) ◽  
pp. 775-781
Author(s):  
Norfariza Wahab ◽  
◽  
Yumi Inatsugu ◽  
Satoshi Kubota ◽  
Soo-Young Kim ◽  
...  
Keyword(s):  
Flow Stress ◽  
Strain Rate ◽  
Cutting Forces ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Edge ◽  
Cutting Process ◽  
Machining Parameters ◽  
Friction Characteristics ◽  
High Speed Cutting

In recent times, numerical simulation techniques have been commonly used to estimate and predict machining parameters such as cutting forces, stresses, and temperature distribution. However, it is very difficult to estimate the flow stress of a workpiece and the friction characteristics at a tool/chip interface, particularly during a high-speed cutting process. The objective of this study is to improve the accuracy of the present method and simultaneously determine the characteristics of the flow stress of a workpiece and friction at the cutting edge under a high strain rate and temperature during the cutting process. In this study, the Johnson-Cook (JC) flow stress model is used as a function of strain, strain rate, and temperature. The friction characteristic was estimated by minimizing the difference between the predicted and measured results of principal force, thrust force, and shear angle. The shear friction equation was used to estimate the friction characteristics. Therefore, by comparing the measured values of the cutting forces with the predicted results from FEM simulations, an expression for workpiece flow stress and friction characteristics at the cutting edge during a high-speed cutting process was estimated.

Finite Element Analysis of Surface Residual Stress of Titanium Alloy TC4 Based on High Speed Cutting

2012 ◽  
Vol 500 ◽  
pp. 157-162 ◽  
Author(s):  
Zeng Hui Jiang ◽  
Xiao Liang Wang ◽  
Jian Hai Zhang ◽  
Xiao Ye Deng
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
Titanium Alloy ◽  
High Speed ◽  
Numerical Study ◽  
Cutting Speed ◽  
Cutting Process ◽  
Residual Tensile Stress ◽  
High Speed Cutting ◽  
Cutting Surface

Due to the complex structures of aviation products made of titanium alloy TC4, residual stress can be generated by the high speed cutting process at their surface which has an important influence on their fatigue strength and also service life. Therefore, in this paper, a 3D finite element model is built to analyze the cutting process with different tool parameters and to investigate the residual stress inside the processed surface. By the numerical study, when the cutting speed is 140 m/min, the residual tensile stress can be generated in the inner cutting surface, while the compressive residual stress in the outer cutting surface. Residual compressive stress can be enhanced by choosing the smaller tool rake angle, the bigger tool relief angle and the bigger cutting edge radius properly.

Study on Milling Process Based on Finite Element Analysis

2012 ◽  
Vol 468-471 ◽  
pp. 1322-1325
Author(s):  
Yong Liang Zhang ◽  
Rui Jie Wang ◽  
Hong Bin Liu ◽  
Mao Hua Du ◽  
Xiao Dong Xu
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
High Speed ◽  
Cutting Temperature ◽  
Milling Process ◽  
Cutting Process ◽  
Feed Speed ◽  
Element Analysis ◽  
High Speed Cutting ◽  
Deformation Force

The influence of negative chamfers of PCBN milling cutters on cutting process of high speed cutting is studied based on finite element analysis. The milling speed, axial cutting depth and feed speed are all set fixed, while the negative chamfer angle varies. Cutting tool stress, deformation force, and cutting temperature are obtained for cutting process under different negative chamfering Angle,thus providing basis for the selection of tool parameters in practical production.

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