A finite element analysis of orthogonal turning using different tool rake angle

Abstract We describe here the development and testing of a capability for finite element simulation of practical machining operations such as turning and milling, using 3D multi-material, explicit dynamic, Eulerian finite element analysis. In these simulations the workpiece material and the air surrounding it are modeled using Eulerian finite elements and the flow of the workpiece material into the air as a result of the action of the Lagrangian tool can be freely tracked. Tension tests and Taylor impact tests are simulated using the traditional Lagrangian approach as well as the Eulerian approach. Comparison of the results is used to understand the factors affecting the solution accuracy. Simulations of orthogonal machining using this technique show that the side flow of the chip is simulated realistically. Simulations of oblique machining with various rake and inclination angles confirm that the chip flow angle is independent of the rake angle. Inertial effects cause the chip flow angle to differ from the inclination angle as the weight of the chip increases. Simulations of turning and end milling show that chip formation and flow can be simulated ab-initio. The simulation capability described here can provide accurate results for various outputs of interest and is also computationally efficient, allowing a typical analysis to be completed within a day.

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Optimization of Axial Rake Angle for Face Milling Using Taguchi Method and Finite Element Analysis

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.465-466.746 ◽

2013 ◽

Vol 465-466 ◽

pp. 746-750 ◽

Cited By ~ 2

Author(s):

Mohd Riduan Ibrahim ◽

A.R. Abd. Kadir ◽

M.S. Omar ◽

M.H. Osman ◽

S. Sulaiman ◽

...

Keyword(s):

Finite Element Analysis ◽

Finite Element ◽

Optimal Parameter ◽

Signal To Noise Ratio ◽

Cutting Speed ◽

Rake Angle ◽

Milling Process ◽

Face Milling ◽

Element Analysis ◽

Confirmation Test

This study employed the Taguchi approach in combination with finite element analysis (DEFORM3D) to investigate face milling process onto AL6061. The factors studied in this investigation were cutting speed, feed rate, and axial rake angle. The simulation of flank wear was generated according to Usuis wear model though the L9(34) of the orthogonal array experiment. ANOVA analysis and F test were conducted to find the significant factor that contributes to tool wear in the signal to noise ratio. Finally, the confirmation test has been carried out at optimal parameter.

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Cutting Tool Geometry and Parameters Effects on the Force and Temperature in Turning Steel 1040 Using Finite Element Analysis

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.548.465 ◽

2012 ◽

Vol 548 ◽

pp. 465-470

Author(s):

Asaad A. Abdullah ◽

Usama J. Naeem ◽

Cai Hua Xiong

Keyword(s):

Finite Element Analysis ◽

Finite Element ◽

Cutting Forces ◽

Metal Cutting ◽

Cutting Speed ◽

Heat Rate ◽

Cutting Parameters ◽

Rake Angle ◽

Tool Geometry ◽

Element Analysis

In recent years, applications have been proven finite-element method (FEM) in metal-cutting operations to be effective process in the study of cutting and chip formation. In this study, the simulation results are useful for both researchers and machine tool manufacturers for improving the design of cutting parameters. Finite-element analysis (FEA) that used in this study of simulation the cutting parameters and tool geometries effects on the force and temperature in turning AISI 1040. The simulation parameters that used in this study are cutting speed (75 - 300 m/min),feed rate (0.2 mm/rev), cut depth (0.75-1.5 mm), and rake angle (0-20 °). The results of cutting forces were (240 – 520 N), the temperature were (300-420 °C), and the heat rate (14202.3-83772.8 W/mm3) on the cutting edge. The simulation process also show that the increase of cutting speed leads to decrease in the cutting forces, while it has increasing in temperature, and heat rate. Also, the results show that the increase of cutting depth associated increase the cutting force only.

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2D Finite Element Modeling and Analysis of Dry Turning Process of Aeronautic Aluminium Alloy 2024

International Journal of Engineering & Technology ◽

10.14419/ijet.v7i4.16.21710 ◽

2018 ◽

Vol 7 (4.16) ◽

pp. 37-41

Author(s):

Hassan Ijaz ◽

Waqas Saleem ◽

Muhammad Asad ◽

Ahmed Alzahrani ◽

Tarek Mabrouki

Keyword(s):

Finite Element Analysis ◽

Finite Element ◽

Aluminium Alloy ◽

Cutting Forces ◽

Cutting Parameters ◽

Rake Angle ◽

Physical Parameters ◽

Fe Model ◽

Element Analysis ◽

Selection Of

The identification and selection of different physical parameters greatly influence the machining of materials. Cutting speed, feed, tool rake angle and friction are important physical parameters that affect the machining of the materials. Selection of suitable cutting parameters can help to achieve the better machining quality and enhanced tool life. Properly defined FE-model can efficiently simulate the machining processes and thus may help to save the machining cost and expensive materials instead of performing real-life experiments. In the present work, a detailed finite element analysis on the orthogonal cutting of aluminium alloy (AA2024) is conducted to validate the FE-based machining model. Numerically obtained resultant cutting forces are successfully compared with the experimental results for 0.3 and 0.4 mm/rev cutting feeds with 17.5° tool rake angle. Subsequently, the cutting forces are predicted for the selected feeds of 0.35 & 0.45 mm/rev and for different tool rake angles like 9.5°, 13.5° & 21.5° using finite element analysis. Finally, the optimum cutting parameters are suggested for cutting AA2024.

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Study on Plunge Milling Cutter Design with Finite Element Analysis

Materials Science Forum ◽

10.4028/www.scientific.net/msf.836-837.425 ◽

2016 ◽

Vol 836-837 ◽

pp. 425-429

Author(s):

Yuan Sheng Zhai ◽

Hong Li Song ◽

Jing Shu Hu

Keyword(s):

Finite Element Analysis ◽

Finite Element ◽

Geometric Model ◽

Rake Angle ◽

Plunge Milling ◽

Element Analysis ◽

Milling Cutter ◽

Radial Rake Angle ◽

Cutting Vibration ◽

Cutter Design

Plunge milling cutter withstanding greater loads in heavy milling can cause tool breakage, cutting vibration, even chatter. Firstly, geometric model of plunge milling cutter on various combinations of axial rake angle and radial rake angle are established. Secondly, with combination different axial rake angle and radial rake angle of plunge milling cutter under static load, the amount of deformation plunge milling cutter are calculated by finite element analysis. Finally, the plunge milling cutter first six natural frequencies are given in plunge milling cutter modal analysis with finite element analysis. The results show that minimum total deformation of plunge milling cutter is given with the axial rake angle 5° and radial rake angle-5 ° of the cutter and when the tool working at frequencies up to 10012HZ has caused vibration within the XY plane.

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