Influence of feed per tooth on tool wear based on 3D finite element simulation in micro-milling of Inconel 718

2017 ◽  
Vol 69 (4) ◽  
pp. 585-590 ◽  
Author(s):  
Xiaohong Lu ◽  
FuRui Wang ◽  
Zhenyuan Jia ◽  
Likun Si ◽  
Yongqiang Weng
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Finite Element Simulation ◽  
Inconel 718 ◽  
Chip Thickness ◽  
Micro Milling ◽  
Wear Depth ◽  
Content Type ◽  
Element Simulation ◽  
The Relationship

Purpose This paper aims to predict tool wear and reveal the relationship between feed per tooth and tool wear in micro-milling Inconel 718 process. Design/methodology/approach To study and solve the tool wear problem in micro-milling of Inconel 718 micro components, in this paper, the investigation of micro-milling Inconel 718 process was implemented based on DEFORM finite element simulation, and tool wear depth of micro-milling cutter acted as output. Findings Different from the traditional macro milling process, diameter reduction percentage and average flank wear length decreased with the increase of feed per tooth; tool wear depth decreased when the feed per tooth was less than the minimum chip thickness. Originality/value At present, research on the prediction of tool wear in micro-milling of Inconel 718 has never been publicly reported. This study is significant to reveal the relationship between cutting parameters (feed per tooth) and tool wear in micro-milling Inconel 718.

The flank wear prediction in micro-milling Inconel 718

2018 ◽  
Vol 70 (8) ◽  
pp. 1374-1380 ◽  
Author(s):  
Xiaohong Lu ◽  
FuRui Wang ◽  
Zhenyuan Jia ◽  
Steven Y. Liang
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Flank Wear ◽  
Milling Process ◽  
Micro Milling ◽  
Wear Prediction ◽  
Content Type ◽  
Micro Tool

Purpose Cutting tool wear is known to affect tool life, surface quality, cutting forces and production time. Micro-milling of difficult-to-cut materials like Inconel 718 leads to significant flank wear on the cutting tool. To ensure the respect of final part specifications and to study cutting forces and tool catastrophic failure, flank wear (VB) has to be controlled. This paper aims to achieve flank wear prediction during micro-milling process, which fills the void of the commercial finite element software. Design/methodology/approach Based on tool geometry structure and DEFORM finite element simulation, flank wear of the micro tool during micro-milling process is obtained. Finally, experiments of micro-milling Inconel 718 validate the accuracy of the proposed method for predicting flank wear of the micro tool during micro-milling Inconel 718. Findings A new prediction method for flank wear of the micro tool during micro-milling Inconel 718 based on the assumption that the wear volume can be assumed as a cone-shaped body is proposed. Compared with the existing experiment techniques for predicting tool wear during micro-milling process, the proposed method is simple to operate and is cost-effective. The existing finite element investigations on micro tool wear prediction mainly focus on micro tool axial wear depth, which affects size accuracy of machined workpiece seriously. Originality/value The research can provide significant knowledge on the usage of finite element method in predicting tool wear condition during micro-milling process. In addition, the method presented in this paper can provide support for studying the effect of tool flank wear on cutting forces during micro-milling process.

Simulation of hot high-speed yielding of intermetallic titanium alloy VTI-4 under conditions of high-speed loading

2020 ◽  
Vol 0 (12) ◽  
pp. 10-16
Author(s):  
V.V. Avtaev ◽  
◽  
D. V. Grinevich ◽  
A. V. Zavodov
Keyword(s):  
Finite Element ◽  
Titanium Alloy ◽  
Strain Rate ◽  
Finite Element Simulation ◽  
Modulus Of Elasticity ◽  
High Speed ◽  
Residual Deformation ◽  
Test Results ◽  
Element Simulation ◽  
The Relationship

Yielding tests of VTI-4 alloy specimens have been carried out at temperature 1010 °C under conditions of high-speed loading. Based on the test results the modulus of elasticity as well as axial and radial residual deformation values in the end and central zones for each loading stage were determined. Fitting criteria for finite element simulation and the experiment are proposed with tracing VTI-4 alloy diagram deformation at temperature 1010 °C and strain rate of 2.5 sec–1. As a result of finite element simulation the relationship between the material structures obtained during high-speed yielding and the deflected modes in different zones was determined.

Finite Element Simulation and Experimental Research on Micro-Milling Process of Titanium Alloy

2012 ◽  
Vol 522 ◽  
pp. 245-248 ◽  
Author(s):  
Hai Tao Liu ◽  
Ya Zhou Sun ◽  
De Bin Shan ◽  
Yan Quan Geng
Keyword(s):  
Finite Element ◽  
Titanium Alloy ◽  
Finite Element Simulation ◽  
Large Scale ◽  
Simulation Analysis ◽  
Cutting Speed ◽  
Micro Milling ◽  
Element Analysis ◽  
Element Simulation ◽  
Cutting Heat

There are lots of titanium alloy parts which have large-scale micro-structures in astronautic structure and medical implants, so the micro milling becomes one of the effective processing methods in getting the surface micro-structure. Because the titanium alloy has high caking property in processing, it needs a research on the cutting heat and force in order to get better machining precision and surface quality. According to the finite element theory in elastic and plasticity, the influence of cutting speed to the cutting heat and force is got by finite element simulation analysis to the titanium material TC4 in cutting process. It can get the simulation results of cutting heat and force in the micro milling processing by finite element analysis, and then compared, the basic influence which the cutting speed to the cutting heat and force is got. The correctness of the result is checked through cutting experiments.

Finite element simulation of machining Inconel 718 alloy including microstructure changes

2014 ◽  
Vol 88 ◽  
pp. 110-121 ◽  
Author(s):  
F. Jafarian ◽  
M. Imaz Ciaran ◽  
D. Umbrello ◽  
P.J. Arrazola ◽  
L. Filice ◽  
...  
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Inconel 718 ◽  
Inconel 718 Alloy ◽  
Microstructure Changes ◽  
Element Simulation

Effects of the Flow Stress in Finite Element Simulation of Machining Inconel 718 Alloy

2014 ◽  
Vol 611-612 ◽  
pp. 1210-1216 ◽  
Author(s):  
Farshid Jafarian ◽  
Mikel Imaz Ciaran ◽  
Pedro José Arrazola ◽  
Luigino Filice ◽  
Domenico Umbrello ◽  
...  
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Inconel 718 ◽  
Orthogonal Cutting ◽  
Material Model ◽  
Material Behavior ◽  
Machining Process ◽  
Inconel 718 Alloy ◽  
Element Simulation ◽  
Inconel 718 Superalloy

Inconel 718 superalloy is one of the difficult-to-machine materials which is employed widely in aerospace industries because of its superior properties such as heat-resistance, high melting temperature, and maintenance of strength and hardness at high temperatures. Material behavior of the Inconel 718 is an important challenge during finite element simulation of the machining process because of the mentioned properties. In this regard, various constants for Johnson–Cook’s constitutive equation have been reported in the literature. Owing to the fact that simulation of machining process is very sensitive to the material model, in this study the effect of different flow stresses were investigated on outputs of the orthogonal cutting process of Inconel 718 alloy. For each model, the predicted results of cutting forces, chip geometry and temperature were compared with experimental results of the previous work at the different feed rates. After comparing the results of the different models, the most suitable Johnson–Cook’s material model was indentified. Obtained results showed that the selected material model can be used reliably for machining simulation of Inconel 718 superalloy.

Finite Element Simulation of the Cutting Process for Inconel 718 Alloy Using a New Material Constitutive Model

2016 ◽  
Vol 693 ◽  
pp. 1046-1053
Author(s):  
Xiang Yu Wang ◽  
Chuan Zhen Huang ◽  
Jun Wang ◽  
Bin Zou ◽  
Guo Liang Liu ◽  
...  
Keyword(s):  
Finite Element ◽  
Constitutive Model ◽  
Finite Element Simulation ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Cutting Process ◽  
Inconel 718 Alloy ◽  
Cutting Edge Radius ◽  
Material Constitutive Model ◽  
Element Simulation

Inconel 718 alloy is a typical difficult-to-cut material and widely used in the aerospace industry. Finite element simulation is an efficient method to investigate the cutting process, whereby a work material constitutive model plays an important role. In this paper, finite element simulation of the cutting process for Inconel 718 alloy using a new material constitutive model for high strain rates is presented. The effect of tool cutting edge radius on the cutting forces and temperature is then investigated with a view to facilitate cutting tool design. It is found that as the cutting edge radius increases, the characteristics of tool-work friction and the material removal mechanisms change, resulting in variation in cutting forces and temperature. It is shown that a smaller cutting edge radius is preferred to reduce the cutting forces and cutting temperature.

Cu/SnAgCu/Cu TLP with different thicknesses for 3D IC

2017 ◽  
Vol 29 (3) ◽  
pp. 151-155 ◽  
Author(s):  
Liang Zhang ◽  
Zhi-quan Liu ◽  
Fan Yang ◽  
Su-juan Zhong
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Integrated Circuit ◽  
Three Dimensional ◽  
Transient Liquid Phase ◽  
Compound Layer ◽  
Intermetallic Compound Layer ◽  
3D Ic ◽  
Content Type ◽  
Element Simulation

Purpose This paper aims to investigate Cu/SnAgCu/Cu transient liquid phase (TLP) bonding with different thicknesses for three-dimensional (3D) integrated circuit (IC). Design/methodology/approach This paper includes experiments and finite element simulation. Findings The growth rate of the intermetallic compound layer during TLP soldering was calculated to be 0.6 μm/s, and the small scallop-type morphology Cu6Sn5 grains can be observed. With the decrease in thickness in solder joint, the thickness of intermetallic compounds represents the same size and morphology, but the size of eutectic particles (Ag3Sn, Cu6Sn5) in the matrix microstructure decrease obviously. It is found that with the increase in thickness, the tensile strength drops obviously. Based on finite element simulation, the smaller value of von Mises demonstrated that the more reliability of lead-free solder joints in 3D IC. Originality/value The Cu/SnAgCu/CuTLPbondingwithdifferentthicknessesfor3D IC was investigated.

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