Rapid Finite Element Prediction on Machining Process

2013 ◽  
Author(s):  
Long Meng ◽  
Xueping Zhang ◽  
Anil K. Srivastava
Keyword(s):  
Finite Element ◽  
Programming Model ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Machining Process ◽  
Fe Model ◽  
Machining Processes ◽  
Machined Surface ◽  
Element Analysis ◽  
Python Language

Finite Element Analysis (FEA) is widely used to simulate machining processes. However, in general, it is time consuming, error-prone, and requires repeated efforts to establish a verified successful Finite Element (FE) model. To rapidly investigate the effects of parameters such as tool angle, feed rate, cutting speed, and temperatures generated during the machining process, an efficient approach is proposed in this paper. The technique has been used to achieve rapid FF simulation during turning and milling processes using Python language programming of Abaqus. Sub-model 1 is programmed to simulate the chip formation process in Abaqus/Explicit. Sub-model 2 is programmed to simulate the cooling spring-back process by importing the machined surface into Abaqus/Implicit. The proposed method is capable of simulating the chip morphology, stress, strain and temperature of the machining process with different parameters immediately. The established FE models are automatically solved in batch by programming script. Post-processing is programmed by Abaqus script to easily achieve and evaluate the simulation results. The Programmed FE models are validated in terms of the predicted chip morphology, cutting forces and residual stresses. This method is extraordinarily efficient saving more than 33% simulation time in comparison to existing FEA approach used for machining processes. Moreover, the script is concise, easy to debug, and effectively avoiding interactive mistakes. The rapid programming model provides a novel, efficiency and convenient approach to thoroughly investigate the effects of a large number of parameters on machining processes.

scholarly journals Analysis of Forces in Vibro-Impact and Hot Vibro-Impact Turning of Advanced Alloys

2011 ◽  
Vol 70 ◽  
pp. 315-320 ◽  
Author(s):  
Riaz Muhammad ◽  
Agostino Maurotto ◽  
Anish Roy ◽  
Vadim V. Silberschmidt
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Three Dimensional ◽  
Element Model ◽  
Machining Process ◽  
Strain Rates ◽  
Machining Processes ◽  
Machined Surface ◽  
Cutting Zone

Analysis of the cutting process in machining of advanced alloys, which are typically difficult-to-machine materials, is a challenge that needs to be addressed. In a machining operation, cutting forces causes severe deformations in the proximity of the cutting edge, producing high stresses, strain, strain-rates and temperatures in the workpiece that ultimately affect the quality of the machined surface. In the present work, cutting forces generated in a vibro-impact and hot vibro-impact machining process of Ti-based alloy, using an in-house Ultrasonically Assisted Turning (UAT) setup, are studied. A three-dimensional, thermo-mechanically coupled, finite element model was developed to study the thermal and mechanical processes in the cutting zone for the various machining processes. Several advantages of ultrasonically assisted turning and hot ultrasonically assisted turning are demonstrated when compared to conventional turning.

Finite Element Analysis of the Effect of Cutting Speed on the Orthogonal Turning of A359/SiCp MMC

2016 ◽  
Vol 852 ◽  
pp. 304-310
Author(s):  
M.M. Thamizharasan ◽  
Y.J. Nithiya Sandhiya ◽  
K.S. Vijay Sekar ◽  
V.V. Bhanu Prasad
Keyword(s):  
Finite Element ◽  
Matrix Material ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Fe Model ◽  
Element Analysis ◽  
Damage And Fracture ◽  
Orthogonal Turning ◽  
The Matrix ◽  
Cutting Speeds

The application of Metal Matrix Composite (MMC) has been increasing due to its superior strength and wear characteristics but the major challenge is its poor machinability due to the presence of reinforcement in the matrix which is a hindrance during machining. The material behaviour during machining varies with respect to input variables. In this paper the effect of cutting speed during the orthogonal turning of A359/SiCp MMC with TiAlN tool insert is analysed by developing a 2D Finite Element (FE) model in Abaqus FEA code. The FE model is based on plane strain formulation and the element type used is coupled temperature displacement. The matrix material is modeled using Johnson–Cook (J-C) thermal elastic–plastic constitutive equation and chip separation is simulated using Johnson–Cook’s model for progressive damage and fracture with parting line. Particle material is considered to be perfectly elastic until brittle fracture. The tool is considered to be rigid. The FE model analyses the tool interaction with the MMC and its subsequent effects on cutting forces for different cutting speeds and feed rates. The chip formation and stress distribution are also studied. The FE results are validated with the experimental results at cutting speeds ranging from 72 – 188 m/min and feed rates ranging from 0.111 – 0.446 mm/rev at constant depth of cut of 0.5mm.

scholarly journals FEM-based comparative study of SQUARE & RHOMBIC INSERT machining performance during turning of AISI-D3 steel

2021 ◽  
Vol 13 (2) ◽  
pp. 143-148
Author(s):  
Anastasios Tzotzis ◽  
◽  
Nikolaos Efkolidis ◽  
Gheorghe Oancea ◽  
Panagiotis Kyratsis ◽  
...  
Keyword(s):  
Finite Element ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
The Finite Element Method ◽  
Machining Simulation ◽  
Machining Performance ◽  
Machining Processes ◽  
Element Analysis ◽  
Friction Forces ◽  
Aisi D3 Steel

Nowadays, employment of the Finite Element Method (FEM) in machining simulation is a common practice to decrease development times and costs, as well as to investigate numerous parameters that affect machining processes. In the present work, the 3D modelling of AISI-D3 hard turning with both square and rhombic inserts is being presented by utilizing a commercially available Finite Element Analysis (FEA) software. Eighteen tests were carried out based on cutting conditions that are recommended for the used tools. Specifically, three levels of cutting speed (75m/min, 110m/min and 140m/min), three levels of feed (0.12mm/rev, 0.16mm/rev and 0.20mm/rev) and depth of cut equal to 0.40mm for all tests, were applied. In order to describe the complex factors that define the model, such as the friction forces, the heat transfer and the pressure due to contact between the tool and the workpiece, a number of acknowledged models were utilized. A comparison of the performance between the two types of tools was made with respect to the developed machining forces and temperature distribution on the workpiece. The findings of the investigation indicate that the specific square tools produce higher values of forces compared to the rhombic ones and approximately the same temperature patterns on the workpiece. The average increase on the produced cutting forces is about 26.4%.

Cutting Force Experiment and Simulation by Hard Turning GCr15 Bearing Steel with High Speed Considering Cutting Edge Preparation

2006 ◽  
Vol 532-533 ◽  
pp. 845-848
Author(s):  
Yu Wang ◽  
Fu Gang Yan ◽  
Jing Shu Hu ◽  
Tao Chen ◽  
Zhen Chang ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Finite Element ◽  
Cutting Forces ◽  
High Speed ◽  
Hard Turning ◽  
Cutting Speed ◽  
Bearing Steel ◽  
Machined Surface ◽  
Element Analysis ◽  
Gcr15 Bearing Steel

In this study, hard turning GCr15 bearing steel with high cutting speed is experimental investigated the influence of the CB7015WH insert with chamfer edge and Safe-Lock and the CB7015 insert with a combination of hone radius and a chamfer edge on cutting forces and surface roughness of machined surface. Experimental results show that the cutting forces of the chamfer edge and Safe-Lock is smaller than that of the combination of hone radius and a chamfer edge. Moreover, surface roughness of machined surface with the CB7015WH insert is better. A coupled thermo-mechanical 2D finite element model with general finite element analysis software Deform 2D.8.1 is developed for the influence of two kinds of inserts on cutting forces and effective stress. The simulation results are compared with experimental data and found to be in good agreement.

A Finite Element Analysis for the Characteristics of Cutting Parameters in 3D Oblique Milling Process

2010 ◽  
Vol 97-101 ◽  
pp. 3010-3013
Author(s):  
Guo Hua Qin ◽  
S.Q. Xin ◽  
Dong Lu ◽  
Yi Ming Rong
Keyword(s):  
Finite Element ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Element Model ◽  
Milling Process ◽  
Machining Process ◽  
Element Analysis ◽  
Complete Procedure ◽  
Commercial Software Package ◽  
Chip Removal

In the field of aeronautical and astronautical manufacturing, milling is a basic machining process by which a surface is generated by progressive chip removal. Therefore, this paper reports a complete procedure of the finite element model for the 3D oblique milling process using the commercial software package ABAQUS. Effect of various parameters on cutting forces is mainly discussed. The model correctly exhibits the observed transition from small to large force with increasing cutting speed and cutting depth.

On the Flow Stress Model Selection for Finite Element Simulations of Machining of Ti6Al4V

2014 ◽  
Vol 611-612 ◽  
pp. 1274-1281 ◽  
Author(s):  
Stano Imbrogno ◽  
Giovanna Rotella ◽  
Domenico Umbrello
Keyword(s):  
Finite Element ◽  
Flow Stress ◽  
Chip Morphology ◽  
Experimental Tests ◽  
Finite Element Method Simulation ◽  
Machining Process ◽  
Stress Model ◽  
Machining Processes ◽  
Flow Stress Model ◽  
Materials Flow

Numerical simulation of machining processes represents a promising tool able to reproduce the cutting conditions without the need to perform a large number of experimental tests. In order to obtain reliable results from the finite element method simulation, is then necessary to properly set up the simulation conditions and to implement the most suitable materials behavior according to the real workpiece characteristics. These data are available in commercial softwares libraries but often they have difficulties to properly represent the machined workpiece behavior. Thus, advanced model are implemented in the software to improve the simulations performance and to obtain realistic results. In this work, the more suitable materials flow stress, within those proposed in literature, is sought to simulate the machining process of Ti6Al4V. The results of the simulations have been compared with those obtained experimentally in terms of temperature, chip morphology and cutting force. The results confirm the need to properly select the materials flow stress model according to the physical sample.

3D Finite Element Analysis of Pile-up Formation in Abrasive Machining at Low Speed

2011 ◽  
Vol 175 ◽  
pp. 211-214
Author(s):  
Wei Yu ◽  
Qiang Feng ◽  
Cheng Zu Ren
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
Abrasive Particle ◽  
Cutting Speed ◽  
Machining Process ◽  
Abrasive Machining ◽  
Element Analysis ◽  
3D Finite Element ◽  
3D Finite Element Analysis ◽  
Pile Up

Abrasive machining is widely used as final machining process. It is still challenged to investigate the fundamental knowledge on the formation mechanism of groove and pile-up in single abrasive particle cutting. A 3D finite element analysis model to simulate single abrasive particle scratching on bearing steel (52100) workpiece with low cutting speed is proposed. An adaptive meshing technique is applied to handle large mesh deformation problem of the scratching process. The formation process of groove and pile-up for workpiece material is indentified qualitatively. The simulated results show that cutting speed has little effect on lateral profile. The height and area of pile-up increase with increase of depth of cut.

A Study on the High Speed Face Milling of Ti-6Al-4V Alloy

Manufacturing ◽  
2002 ◽  
Author(s):  
Balkrishna Rao ◽  
Yung C. Shin
Keyword(s):  
Tool Wear ◽  
Surface Integrity ◽  
Experimental Analysis ◽  
High Speed ◽  
Numerical Study ◽  
Cutting Speed ◽  
Chip Morphology ◽  
Face Milling ◽  
Machined Surface ◽  
Element Analysis

This paper is concerned with the experimental and numerical study of the high speed face milling of Ti-6Al-4V titanium alloy. Machining is carried out by uncoated carbide and polycrystalline diamond cutters in the presence of an abundant supply of coolant. Experimental analysis is conducted in terms of cutting forces, chip morphology, surface integrity and tool wear. The experimental analysis is supplemented by simulations from the finite element analysis where needed. The highest cutting speed realized for both the cutting tool materials is 600 sfpm with the diamond cutter operating at feeds lower than that for carbide. Good surface integrity in terms of residual stress and surface finish is achieved under the machining conditions used with limited tool wear. Residual stresses imparted to the machined surface are compressive with the diamond tool yielding higher values and are the most sensitive to feed. Tool wear patterns are described in terms of various cutting conditions.

Finite Element Modeling on Dislocation Density and Grain Size Evolution in Machined Surface

2013 ◽  
Author(s):  
Liqiang Ding ◽  
Xueping Zhang ◽  
C. Richard Liu
Keyword(s):  
Grain Size ◽  
Dislocation Density ◽  
Orthogonal Cutting ◽  
Cutting Speed ◽  
Experimental Tests ◽  
Rake Angle ◽  
Machining Process ◽  
Fe Model ◽  
Machined Surface ◽  
Size Evolution

Machining process usually induces Severe Plastic Deformation (SPD) in the chip and machined surface, which will further lead to rapid increase of dislocation density and alteration of grain size in micro-scale. This paper presents a novel FE model to simulate the dislocation density and grain size evolution in the machined surface and subsurface generated from the orthogonal cutting process of Al6061-T6. A dislocation density model of microstructure evolution is implemented in the FE model as a user-defined subroutine written in FORTRAN. The model can predict the microstructure characteristic in a machined surface. The predicted chip thicknesses, cutting forces, distributions of dislocation density and grain size are verified by the experimental tests of the chip, forces, microstructure and micro-hardness. The predicted results show that the dislocation density decreases along the depths of machined surface; whereas the grain size shows an opposite tendency. Dislocation density in machined surface decreases and grain size increases when cutting speed increases. Higher cutting speeds are associated with thinner deformation layers. Dislocation density in a machined surface decreases initially and then increases with feed rates. Dislocation density increases significantly when cutting tool has a larger negative rake angle. The bigger negative rake angles further lead to the thicker deformation layers in machined surface.

On Saw-Tooth Chip Formation in High Speed Cutting GH4169

2007 ◽  
Vol 10-12 ◽  
pp. 359-363 ◽  
Author(s):  
Dong Jin Zhang ◽  
Gang Liu ◽  
X. Sun ◽  
Ming Chen
Keyword(s):  
Finite Element ◽  
High Speed ◽  
Cutting Speed ◽  
Chip Morphology ◽  
High Yield ◽  
Forming Process ◽  
Element Analysis ◽  
High Speed Cutting ◽  
Nickel Based Superalloy ◽  
Wide Range

The nickel-based superalloy GH4169 is a typical difficult-to-cut material, but it has been used in a good many kinds of aeronautical key structures because of its high yield stress and anti-fatigue performance at the temperature below 650°C. In this paper, finite element method (FEM) was introduced to study the saw-tooth chip forming process in detail when machining nickel-based superalloy GH4169. By the way of Lagrangian visco-elastic plastic approach, adiabatic shear band (ASB) was simulated in high speed machining condition by general commercial finite element code, and the mechanism of the adiabatic shearing phenomenon at primary shear zone was analyzed with the help of finite element analysis (FEA). The comprehensive comparisons of saw-tooth chip morphology under a wide range of cutting speed were also presented.

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