Finite Element Modeling of Stresses Induced by High Speed Machining With Round Edge Cutting Tools

2005 ◽  
Author(s):  
Tugrul O¨zel ◽  
Erol Zeren
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Surface Properties ◽  
High Speed ◽  
Cutting Tool ◽  
Cutting Tools ◽  
Material Behavior ◽  
High Speed Machining ◽  
Element Modeling ◽  
Work Material

High speed machining (HSM) produces parts with substantially higher fatigue strength; increased subsurface micro-hardness and plastic deformation, mostly due to the ploughing of the cutting tool associated with residual stresses, and can have far more superior surface properties than surfaces generated by grinding and polishing. In this paper, a dynamics explicit Arbitrary Lagrangian Eulerian (ALE) based Finite Element Method (FEM) modeling is employed. FEM techniques such as adaptive meshing, explicit dynamics and fully coupled thermal-stress analysis are combined to realistically simulate high speed machining with an orthogonal cutting model. The Johnson-Cook model is used to describe the work material behavior. A detailed friction modeling at the tool-chip and tool-work interfaces is also carried. Work material flow around the round edge-cutting tool is successfully simulated without implementing a chip separation criterion and without the use of a remeshing scheme. Finite Element modeling of stresses and resultant surface properties induced by round edge cutting tools is performed as case studies for high speed machining of AISI 1045 and AISI 4340 steels, and Ti6Al4V titanium alloy.

Friction Induced Vibration in Windscreen Wiper Contacts

2015 ◽  
Vol 137 (4) ◽  
Author(s):  
Tom Reddyhoff ◽  
Oana Dobre ◽  
Julian Le Rouzic ◽  
Nicolaas-Alexander Gotzen ◽  
Hilde Parton ◽  
...  
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
High Speed ◽  
Contact Angles ◽  
Element Modeling ◽  
Friction Measurements ◽  
Mixed Lubrication Regime ◽  
Bending Modes ◽  
Intermediate Surface ◽  
Friction Induced Vibration

This research is aimed at understanding the mechanisms that give rise to friction induced noise in automotive windscreen wipers, with a focus on frequencies between 500 and 3500 Hz. To study this phenomenon, experimental friction, sound, and high-speed video measurements are combined with finite element modeling of a rubber wiper/glass contact. In agreement with previous research, simultaneous sound and friction measurements showed that wiper noise in this frequency range results from the negative damping effect caused by the dependence of friction on speed in the mixed lubrication regime. Furthermore, during sliding, the friction induced noise recorded by the microphone occurred in one of two frequency ranges (close to 1000 Hz and between 2000 and 2500 Hz). These coincided closely with the eigen-frequencies of first two bending modes, predicted by finite element modeling. Experimental observations also showed the wiper to be oscillating backward and forward without any torsional motion and that the thickness of the glass had no effect on the emitted noise. These observations highlight how friction induced noise—although caused by conditions within contact—has characteristics that are determined by the structure of the excited component. A number of additional findings are made. Most importantly, both experiment and finite element modeling showed that the presence of water in contact with the wiper modulates the frequency and amplitude of the emitted noise by effectively adding mass to the vibrating system. While this is occurring, Faraday-like standing waves are observed in the water. In addition to this, friction induced vibration is shown only to occur for glass surfaces with intermediate surface energies, which is possibly due to high contact angles preventing water reaching the contact. Based on the understanding gained, a number of suggestions are made regarding means of reducing windscreen wiper noise.

scholarly journals Finite element modeling of high-speed milling 7050-T7451 alloys

2020 ◽  
Vol 43 ◽  
pp. 471-478
Author(s):  
Xianghui Huang ◽  
Jinyang Xu ◽  
Ming Chen ◽  
Fei Ren
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
High Speed ◽  
High Speed Milling ◽  
Element Modeling

Investigation on Chip Formation during Machining Using Finite Element Modeling

2012 ◽  
Vol 505 ◽  
pp. 31-36 ◽  
Author(s):  
Moaz H. Ali ◽  
Basim A. Khidhir ◽  
Bashir Mohamed ◽  
A.A. Oshkour
Keyword(s):  
Finite Element ◽  
Tool Wear ◽  
Finite Element Modeling ◽  
Chip Formation ◽  
Cutting Tool ◽  
Chip Morphology ◽  
Machining Process ◽  
Element Modeling ◽  
Segmented Chip ◽  
Cutting Speeds

Titanium alloys are desirable materials for aerospace industry because of their excellent combination of high specific strength, lightweight, fracture resistant characteristics, and general corrosion resistance. Therefore, the chip morphology is very important in the study of machinability of metals as well as the study of cutting tool wear. The chips are generally classified into four groups: continuous chips, chips with built-up-edges (BUE), discontinuous chips and serrated chips. . The chip morphology and segmentation play a predominant role in determining machinability and tool wear during the machining process. The mechanics of segmented chip formation during orthogonal cutting of titanium alloy Ti–6Al–4V are studied in detail with the aid of high-speed imaging of the chip formation zone. The finite element model of chip formation of Ti–6Al–4V is suggested as a discontinuous type chip at lower cutting speeds developing into a continuous, but segmented, chip at higher cutting speeds. The prediction by using finite-element modeling method and simulation process in machining while create chips formation can contribute in reducing the cost of manufacturing in terms of prolongs the cutting tool life and machining time saving.

Modeling and Experimental Research Regarding the Temperature Distribution along Curved Cutting Edges

2014 ◽  
Vol 1036 ◽  
pp. 259-264
Author(s):  
Nicușor Baroiu ◽  
Doina Boazu ◽  
Silviu Berbinschi ◽  
Virgil Teodor
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Cutting Tools ◽  
Chip Thickness ◽  
Cutting Edge ◽  
Actual Process ◽  
Element Modeling ◽  
Temperature State ◽  
Machining Speed ◽  
Twist Drills

The curved cutting edge determines a variable chip thickness that leads to various may energetically load along the cutting edge. For twist drill with curved cutting edges, the machining speed variation along the major cutting edge is significant. The points belong to the drills periphery work with an increased machining speed. The thick of the detached chip by these cutting zones downwards to the periphery, versus the thick corresponding to the zones at the drills axis, may leads, in some conditions, to the evenness of the energetically load along the cutting edge, with direct influence regarding the cutting tools wearing mechanism. In this paper are presented modeling with finite elements developed in the Ansys Workbench environment, regarding the energetically load and the temperature state along the cutting edge with variable working angle, characteristic for twist drills with curved cutting edges. The modeling was made comparative with the drill with straight lined cutting edges, for the same working conditions. In the same time, presents an experimental record of an actual process. It was recorded the temperature along the cutting edge with a variable working angle in a turning process with transversal feed. There are presented results of the finite element modeling and of the experiment that simulated the cutting process at drilling. The experimental results of the finite element modeling confirm the trend for temperature evenness along the cutting edge with variable working angle regarding the drills with straight-line cutting edge.

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