Eulerian Finite Element Analysis of 3D Machining

1999 ◽  
Author(s):  
V. Madhavan ◽  
L. Olovsson ◽  
S. C. Swargam ◽  
R. Agarwal
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
End Milling ◽  
Rake Angle ◽  
Workpiece Material ◽  
Element Analysis ◽  
Flow Angle ◽  
Chip Flow ◽  
Comparison Of The Results ◽  
Side Flow

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.

Composite Drive Shaft Coupling for Future Rotorcraft: A 3D Finite-Element Analysis

1988 ◽  
Author(s):  
R. N. Margasahayam ◽  
H. S. Faust
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Analytical Techniques ◽  
Fe Model ◽  
Design Development ◽  
Element Analysis ◽  
3D Finite Element ◽  
The Finite Element Analysis ◽  
Comparison Of The Results ◽  
3D Finite Element Method

Abstract A finite-element stress analysis of a one-piece, integrated, all-composite shaft and coupling is presented. In addition to a brief discussion of design-driving parameters, some limitations of the analytical techniques used for design development are described. The 3D finite-element method (FEM) was then used to evaluate critical stresses and strains experienced by the shaft coupling. A comparison of the results from the finite-element analysis and those from static bending, axial, and torsional tests conducted on these prototype shafts yielded excellent correlation. Some important considerations in the development of the FE model and the correlation of results with tests, especially in the design of composite materials, are addressed.

The Finite Element Analysis on Can Coiler of Gilling Machine

2012 ◽  
Vol 215-216 ◽  
pp. 837-841 ◽  
Author(s):  
Bin Lin ◽  
Xiao Fei Dong ◽  
Guan Wei Zhang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Coordinate System ◽  
Contact Analysis ◽  
Element Analysis ◽  
The Finite Element Analysis ◽  
Comparison Of The Results ◽  
Distribution Of Stress ◽  
The Impact ◽  
Bearing Structure

This paper first analyzes the structure of can coiler to estimate the load of the internal bearing structure and then uses the Pro/e software to calculate the mass and centroid of the can coiler, in the same coordinate system to determine the load of the bearing. Next, the intensity of bearing under different conditions will be analyzed by using the ANSYS contact analysis module, from which the distribution of stress and size of extreme value can be observed. At last, the impact of load changes on the stress will be analyzed based on the comparison of the results.

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

2013 ◽  
Vol 465-466 ◽  
pp. 746-750 ◽  
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.

New realistic hypothesis on corner stiffness of right-angle frames for increased analysis accuracy

2015 ◽  
Vol 231 (9) ◽  
pp. 1738-1748
Author(s):  
Young-Doo Kwon ◽  
Jin-Sik Han
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Equivalent Stress ◽  
Frame Structure ◽  
Element Analysis ◽  
Optimal Dimension ◽  
Various Boundary Conditions ◽  
Wide Range ◽  
Von Mises ◽  
Comparison Of The Results

Structural elements like bars, trusses, beams, frames, plates, and shells have long been used in structures and machines because of their large stiffness-to-weight ratios. The Euler–Bernoulli theory for beam elements is currently used in a wide range of engineering fields. Frames may essentially be considered to be a type of general beam with axial loads. In the analysis of a right-angle frame, the stiffness of a corner has been assumed to be infinite, which is allowable only when the frame is sufficiently slender. However, a comparison of the results of a finite element analysis showed that the assumption of rigid corner stiffness is unacceptable for most cases because of the considerable errors that result. To resolve this problem, we assumed that the stiffness of a corner in a right-angle frame was finite, which is mostly the case, and solved the problem of a right-angle frame with round corners under internal pressure. Using the derived formula based on the assumption of finite corner stiffness and the formula for the round corner stiffness, we analyzed the entire right-angle frame structure and compared the results to finite element analysis results. As a final attempt, the quasi-optimal dimension of the corner was found to exhibit the lowest von Mises equivalent stress. This proposed approach could be applied to many problems involving frames with various boundary conditions to improve the accuracy.

Finite Element Analysis on Processing of PCD End-Mill Milling Copper

2020 ◽  
Vol 993 ◽  
pp. 421-426
Author(s):  
Yun Hai Jia ◽  
Chong Hao Quan ◽  
Jian Mei Guo ◽  
Min Wang ◽  
Qin Jian Zhang
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Cutting Force ◽  
Rotation Speed ◽  
End Milling ◽  
Great Influence ◽  
High Wear Resistance ◽  
Work Piece ◽  
Tool Temperature ◽  
Element Analysis

Polycrystalline diamond (PCD), is a tool material and widely used in nonferrous metal processing due to its excellent properties, such as high hardness, high wear resistance, high thermal conductivity and low friction coefficient. Considering the friction between the cutter and the workpiece, the heat generated by the elastic-plastic deformation and the heat transfer between the cutter and the workpiece. The finite element analysis software ABAQUS was used to study the effect of different processing parameters on the temperature field distribution and cutting force of the cutter, in the case of welded PCD double-edge end milling copper. The temperature distribution of cutting tools and the changing trend of cutting force with milling parameters was obtained. These technological parameters include the milling rotation speed n, the axial milling depth ap, and the feed rate f. The simulation results show that the tool temperature increases with the increase of milling depth, feed per revolution and rotation speed. However, the tool temperature has little effect on the tool life. Under the condition of satisfying the work-piece surface quality and machining efficiency, low speed, small milling depth and small feed should be selected as far as possible. Milling depth has a great influence on cutting force. When milling speed is about 2400 r/min, the axial milling depth is 0.3 mm, and the feed is 0.2 mm/r, which can obtain small milling force and lower tool temperature, and further extend the life of PCD tool.

Finite Element Analysis of Blower Impeller Using Cyclic Symmetry

2007 ◽  
Vol 353-358 ◽  
pp. 1082-1085
Author(s):  
Chang Boo Kim ◽  
Young Chul Ahn ◽  
Bo Yeon Kim ◽  
Chong Du Cho ◽  
Hyeon Gyu Beom
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Fourier Transform ◽  
Natural Vibration ◽  
Cyclic Symmetry ◽  
Static Characteristics ◽  
Element Analysis ◽  
The Finite Element Analysis ◽  
Non Linear ◽  
Comparison Of The Results

In this paper, we present an efficient method for conducting a finite element analysis of a structure with cyclic symmetry and apply the method to analyze the natural vibration and linear and non-linear static characteristics of a blower impeller. A blower impeller is composed of circumferentially repeated substructures. The whole structure is partitioned into substructures, and the finite element analysis can thus be performed with one representative substructure by using the transformed equations for each number of nodal diameters, which are derived from a discrete Fourier transform. We calculated the natural vibration and linear and non-linear static characteristics of a blower impeller without a stiffening ring, and with small as well as large stiffening rings, respectively. The accuracy and efficiency of the presented method are verified by comparison of the results obtained from the analysis using a substructure to those obtained using the whole structure.

Finite Element Analysis of Machining Thin-Wall Parts

2010 ◽  
Vol 458 ◽  
pp. 283-288 ◽  
Author(s):  
R. Izamshah R.A. ◽  
John Mo ◽  
Song Lin Ding
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
End Milling ◽  
Operating Cost ◽  
Weight Ratio ◽  
Milling Process ◽  
Machining Process ◽  
Thin Wall ◽  
Structural Components ◽  
Element Analysis

In an attempt to decrease weight, new commercial and military aircraft are designs with unitised monolithic metal structural components which contains of thinner ribs (i.e., walls) and webs (i.e., floors). Most of the unitised monolithic metal structural components are machined from solid plate or forgings with the start-to-finish weight ratio of 20:1. The resulting thin-walled structure often suffers a deformation which causes a dimensional surface error due to the action of the cutting force generated during the machining process. To alleviate the resulting surface errors, current practices rely on machining through repetitive feeding several times and manual calibration which resulting in long cycle times, low productivity and high operating cost. A finite element analysis (FEA) machining model is developed in this project to specifically predict the distortion or deflection of the part during end milling process. The model aims to provide an input for downstream decision making on error compensation strategy when machining a thin-wall unitised monolithic metal structural components. A set of machining tests have been done in order to validate the accuracy of the model and the results between simulation and experiment are found in a good agreement.

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