scholarly journals A Finite Element Study of Large Strain Extrusion Machining Using Modified Zerilli–Armstrong Constitutive Relation

2021 ◽  
Vol 143 (10) ◽  
Author(s):  
Muralimohan Gurusamy ◽  
Karthik Palaniappan ◽  
H. Murthy ◽  
Balkrishna C. Rao
Keyword(s):  
Finite Element ◽  
Constitutive Relation ◽  
Compression Ratio ◽  
Inconel 718 ◽  
Strain Distribution ◽  
Large Strain ◽  
Effective Strain ◽  
Machining Process ◽  
Influence Of Process Parameters ◽  
Chip Compression Ratio

Abstract The objective of this work is to study the performance of modified Zerilli–Armstrong constitutive relation proposed in our previous study for the finite element modeling of a severe plastic deformation technique called large strain extrusion machining. The modified Zerilli–Armstrong constitutive relation is implemented in a finite element model of large strain extrusion machining of Inconel 718 to analyze the influence of process parameters, i.e., the chip compression ratio and tool–chip friction, on deformation, effective strain distribution, and hydrostatic pressure distribution along the extruded chip. The predicted strain values for different chip compression ratios were validated by comparison with those obtained through an analytical model. The finite element predictions also served as a guideline in designing the large strain extrusion-machining setup on which experiments were conducted to generate Inconel 718 foils with superior mechanical properties. The predicted limits of chip compression ratio were in close agreement with experimentally realizable values. Furthermore, the predicted strain distribution through the thickness of the chip was validated with the results of hardness measurement tests. Microstructural characterization of the Inconel 718 foils was carried out by using both optical and transmission-electron microscopic studies in order to reveal the presence of fine-grain structures. The validations showed the effectiveness of the modified Zerilli–Armstrong constitutive relation in modeling large strain extrusion machining—a variant of the conventional machining process.

scholarly journals Machinability analysis of dry and liquid nitrogen–based cryogenic cutting of Inconel 718: experimental and FE analysis

2021 ◽  
Author(s):  
Salman Pervaiz ◽  
Sathish Kannan ◽  
Saqib Anwar ◽  
Dehong Huo
Keyword(s):  
Finite Element ◽  
Compression Ratio ◽  
Inconel 718 ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Contact Length ◽  
Cryogenic Cooling ◽  
Chip Compression Ratio ◽  
Machinability Analysis ◽  
Hot Hardness

Abstract Inconel 718 is famous for its applications in the aerospace industry due to its inherent properties of corrosion resistance, wear resistance, high creep strength, and high hot hardness. Despite the favorable properties, it has poor machinability due to low thermal conductivity and high hot hardness. To limit the influence of high cutting temperature in the cutting zone, application of cutting flood is recommended during the cutting operation. Cryogenic cooling is the recommended method when machining Inconel 718. However, there is very limited literature available when it comes to the numerical finite element modeling of the process. This current study is focused on the machinability analysis of Inconel 718 using numerical approach with experimental validations. Dry and cryogenic cooling methods were compared in terms of associated parameters such as chip compression ratio, shear angle, contact length, cutting forces, and energy consumption for the primary and secondary deformation zones. In addition, parameters related to chip morphology were also investigated under both lubrication methods. Chip formation in cryogenic machining was well captured by the finite element assisted model and found in good agreement with the experimental chip morphology. Both experimental and numerical observations revealed comparatively less chip compression ratio in the cryogenic cooling with larger value of shear plane angle. This results in the smaller tool–chip contact length and better comparative lubrication.

Effect of the Friction Coefficient on Large Strain Extrusion Machining

2013 ◽  
Vol 273 ◽  
pp. 138-142 ◽  
Author(s):  
Ping Lin ◽  
Zi Chun Xie ◽  
Qing Li
Keyword(s):  
Finite Element ◽  
Friction Coefficient ◽  
Nanostructured Materials ◽  
Deformation Behavior ◽  
Large Strain ◽  
Effective Strain ◽  
Finite Element Simulations ◽  
Friction Coefficients ◽  
Simulation Results

The present study focused on the influence of the friction coefficient on the deformation behavior in large strain extrusion machining (LSEM). A series of simulation results of effective strain were obtained under different friction coefficients by conducting finite element simulations with a FEM code. The results show that LSEM can produce different effective strains by changing the friction coefficients, thus enabling the fabrication of bulk nanostructured materials. An analysis of the variation of effective strain through the chip demonstrated that the chip deformed much more inhomogeneously when the friction coefficient became larger. The obtained results can offer valuable guidelines for later LSEM studies.

Research of Formation Mechanics on Nanostructured Chips by Multi-Deformations Based on Finite Element Method

2014 ◽  
Vol 989-994 ◽  
pp. 352-355
Author(s):  
C.L. Wu ◽  
Z.R. Wang ◽  
Wen Zhang
Keyword(s):  
Finite Element Method ◽  
Plastic Deformation ◽  
Finite Element ◽  
Large Strain ◽  
Effective Strain ◽  
Longitudinal Section ◽  
Rake Angle ◽  
Governing Parameter ◽  
Cutting Velocity ◽  
Mean Strain

Formation of chip is a typical severe plastic deformation progress in machining which is only single deformation stage. The rake angle of tool is governing parameter to create large strain imposed in the chip. Effect of rake angle and deformation times on effective strain, mean strain, strain variety and strain rate imposed in the chip are researched respectively. The result of simulation have shown that the chip with large strain and better uniform of strain along the longitudinal section of chip can be produced with negative rake angle at some lower cutting velocity by multi-deformations in large strain machining.

Finite Element Simulation of Cyclic Channel Die Compression with Route A

2010 ◽  
Vol 44-47 ◽  
pp. 1300-1304
Author(s):  
Feng Jian Shi ◽  
Tao Xu ◽  
Sheng Lu ◽  
Lei Gang Wang
Keyword(s):  
Finite Element ◽  
Large Strain ◽  
Effective Strain ◽  
Central Zone ◽  
Peripheral Zone ◽  
Linear Increase ◽  
Rigid Plastic ◽  
Compression Load ◽  
Fine Grained ◽  
Two Stages

In this paper, effective strain and load were simulated by rigid-plastic finite element method (FEM) during cyclic channel die compression (CCDC) with route A, and the optical microstructure was observed. The results show that large strain can be accumulated in the material by CCDC. The load variation includes two stages, slowly linear increase and rapid increase. At the end of the CCDC, the compression load rises rapidly. Apart from the edges of the specimen, the effective strain is higher in the central region and lower at the surrounding region. The effective strain gradient increases with the number of compression. Grain refinement at the central zone is faster due to the strain inhomogeneity. But the peripheral zone is also refined with the number of CCDC. This illustrates CCDC is a promising method for producing bulk ultra-fine grained materials.

Study on Internal Helical Gear Worm Forging by Finite Element Analysis

2013 ◽  
Vol 465-466 ◽  
pp. 1361-1364
Author(s):  
Tung Sheng Yang ◽  
Jia Yu Deng ◽  
Jie Chang
Keyword(s):  
Finite Element ◽  
Strain Distribution ◽  
Effective Strain ◽  
Helical Gear ◽  
The Finite Element Method ◽  
Forming Force ◽  
Element Analysis ◽  
Power Requirement ◽  
Warm Forging ◽  
Forging Load

This study applies the finite element method (FEM) to predict maximum forging load and effective strain in internal helical gear forging. Maximum forging load and effective strain are determined for different process parameters, such as modules, number of teeth, and die temperature of the internal helical gear forging, using the FEM. Finally, the prediction of the power requirement for the internal helical gear warm forging is determined. Therefore, the maximum forming force and strain distribution will be prediction for the different parameters of helical gear worm forging.

Cutting forces analysis of micro-milling process on Inconel 718 – a finite element approach

2020 ◽  
Vol 11 (02) ◽  
pp. 2050011
Author(s):  
Padmaja Tripathy ◽  
Kalipada Maity
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Fem Analysis ◽  
Milling Process ◽  
Machining Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Parameters

This paper presents a modeling and simulation of micro-milling process with finite element modeling (FEM) analysis to predict cutting forces. The micro-milling of Inconel 718 is conducted using high-speed steel (HSS) micro-end mill cutter of 1mm diameter. The machining parameters considered for simulation are feed rate, cutting speed and depth of cut which are varied at three levels. The FEM analysis of machining process is divided into three parts, i.e., pre-processer, simulation and post-processor. In pre-processor, the input data are provided for simulation. The machining process is further simulated with the pre-processor data. For data extraction and viewing the simulated results, post-processor is used. A set of experiments are conducted for validation of simulated process. The simulated and experimental results are compared and the results are found to be having a good agreement.

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.

A Study of Preform Design on Backward Extrusion for Improved Hardness Distribution

2012 ◽  
Vol 445 ◽  
pp. 247-252
Author(s):  
Chin Tarn Kwan ◽  
Zhi Kai Chang
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Strain Distribution ◽  
Effective Strain ◽  
Strain Curve ◽  
Preform Design ◽  
Hardness Distribution ◽  
The Finite Element Method ◽  
Backward Extrusion ◽  
Deform 2D

In this paper, the finite element method is used to investigate the effect of preform shapes on the strain hardening distribution in the wall of the extruded cup of backward extrusion. A series of simulations on the backward extrusion with three different preform shapes (flat, concave and convex) and without preform using the FEM program DEFORM 2D was carried out, respectively. The influence of preform shapes on the effective strain distribution in the extruded wall was examined. A hardness vs. effective strain curve for an annealed AL6061 Aluminum was first obtained using a simple forging test in conjunction with FE simulations, then the curve was used to convert the effective strain distribution into the hardness distribution in the extruded wall. The results of FEM calculations reveal that the concave shape preform has the best effect on the hardness strengthening at the extruded wall of backward extrusion.

Numerical Simulation of Temperature and Effective Strain Distribution of Aluminum Alloy in the Whole Rough Rolling Process

2014 ◽  
Vol 602-605 ◽  
pp. 326-329
Author(s):  
Bo Zhang ◽  
Xiao Ping Liang ◽  
Jun Feng Fu
Keyword(s):  
Mathematical Model ◽  
Finite Element ◽  
Aluminum Alloy ◽  
Process Parameters ◽  
Strain Distribution ◽  
Orthogonal Experiment ◽  
Effective Strain ◽  
Contact Heat ◽  
Finite Element Software ◽  
Rough Rolling

A two-dimensional finite element mathematical model of rough rolling in "1+4" hot continuous rolling of 5052 aluminum alloy was developed by using finite element software Deform, The temperature and effective strain distribution of the strip in different process parameters has been investigated in by simulating the mathematical model in different simulation conditions. The process parameters such as rolling speed, initial temperature, contact heat transfer coefficient between work roll and strip have been considered. The simulation conditions were built by the means of orthogonal experiment. The process parameters, which can make the temperature and effective strain of the strip in a relatively uniformity distribution, were achieved by analyzing the simulation results under different simulation conditions. To judge the uniformity of the temperature and effective strain distribution of the strip quantitative in different simulation conditions, standard deviation has been used as a criterion.

scholarly journals Strain Behavior of Nickel Alloy 200 during Multiaxial Forging through Finite Element Modeling

Metals ◽  
2019 ◽  
Vol 9 (2) ◽  
pp. 132 ◽  
Author(s):  
Faramarz Djavanroodi ◽  
Zahid Hussain ◽  
Osama Irfan ◽  
Fahad Al-Mufadi
Keyword(s):  
Finite Element ◽  
Strain Rate ◽  
Effective Strain ◽  
Homogeneous Microstructure ◽  
Influence Of Process Parameters ◽  
Strain Behavior ◽  
Element Simulation ◽  
Ultrafine Grained ◽  
Average Grain Size ◽  
Nickel 200

Multiaxial forging (MAF) is one of the appealing methods of severe plastic deformation (SPD) techniques to fabricate ultrafine-grained (UFG) materials. In this study; the influence of process parameters such as strain rate; friction; and initial temperature has been assessed through finite element simulation of Nickel 200 alloy. The Johnson–Cook equation was applied in simulating the MAF process. The homogeneous microstructure of a material processed by MAF is an important requirement to obtain uniform mechanical and other properties. The uniformity in properties was evaluated by the investigation of the hardness measurements; effective strain (ES), and inhomogeneous factor (IF) or coefficient of standard deviation. The results showed that the inhomogeneous factor decreases with an increase in strain rate and decrease in temperature. It was found that a more homogeneous structure is observed with an increasing number of MAF cycles and the strain rate strain. Furthermore; the average grain size reduced from 850 nm to 220 nm after three cycles of MAF. Finally; experimental work was performed to validate the results.

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