Numerical Simulation of Pulsed Water Jet Machining of Al 6061-T6 and Ti-6Al-4V

2020 ◽  
Author(s):  
Greg Pasken ◽  
J. Ma ◽  
Muhammad P. Jahan ◽  
Shuting Lei
Keyword(s):  
Tool Wear ◽  
Metal Cutting ◽  
Chip Thickness ◽  
High Heat ◽  
Water Jet ◽  
Orifice Diameter ◽  
Machined Surface ◽  
Al 6061 ◽  
Pulsed Water Jet ◽  
Cutting Processes

Abstract Aluminum, known for its low density and its ability to resist corrosion through passivation, is vitally important to the aerospace industry, transportation, and building industries. The most common problem when machining titanium using traditional metal cutting processes is that tools rapidly wear out and need to be replaced since the variation of chip thickness, high heat stress, high-pressure loads, spring back, and residual stress result in higher tool wear and worse machined surface integrity. Thus, a technique that allows high precision machining of titanium that preserves the integrity of the machined material, reduces tool wear or even eliminates tooling entirely is an important advance. This study examines the ability to machine Al 6061-T6 and Ti-6Al-4V using a pulsed water jet by simulation using ABAQUS Smoothed Particle Hydrodynamics (SPH). The aluminum results showed that between the three diameters the 0.4572 mm orifice is a better choice based upon the percent increase from the orifice diameter; but based off of the kerf, the 0.3556 mm is the better choice. The results show that the 621 MPa has the highest MRR for Al 6061-T6, 232.1 mm3/s. For the four pressure simulations for the titanium, the 138 MPa pressure has the smoothest surface. Even though the volume removed decreased as the pressures increased for the titanium, the MRR increased due to the shorter machining times with 621 MPa pressure having the second highest MRR, 170.051 mm3/s. The results show that overall the 621 MPa is the best choice from the parameters chosen for machining Al 6061-T6 and Ti-6Al-4V.

Numerical Simulation and Experimental Validation of Pure Water Jet Machining of Ti-6Al-4V

2020 ◽  
Author(s):  
Greg Pasken ◽  
J. Ma ◽  
Muhammad P. Jahan ◽  
Shuting Lei
Keyword(s):  
Predictive Modeling ◽  
Metal Cutting ◽  
Removal Rate ◽  
Pure Water ◽  
Surface Profile ◽  
Predictive Modelling ◽  
Water Jet ◽  
The Other ◽  
Orifice Diameter ◽  
Cutting Processes

Abstract The most common problem when machining titanium using traditional metal cutting processes is that tools rapidly wear out and need to be replaced. This study examines the ability of a pure water jet to machine Ti-6Al-4V via simulations using ABAQUS’s Smoothed Particle Hydrodynamics (SPH). These simulations are then validated experimentally at two pressures, 138 MPa and 317 MPa. Using a Maxiem water jet built by Omax, experiments are conducted by creating a series of 5 lines that are 5 inches (127 mm) long placed 0.5 inches (12.7 mm) apart on a 1 mm thick Ti-6Al-4V workpiece. Predictive modeling is also conducted using the two additional pressures 400 MPa and 621 MPa as well as three orifice diameters 0.254 mm, 0.3556 mm, and 0.4572 mm. The simulations are validated at both pressures and had a percent error less than 2.6% which were within the standard deviation of the experimental results. The predictive modeling indicates that the pressures above 317 MPa create a near identical percent increase from the orifice diameter but the kerf has a more noticeable decrease in width of cut as the pressure increases. The 138 MPa has the smoothest surface profile compared to the other pressures. The volume of removed material decreases as the pressure increases but the material removal rate (MRR) increases as the pressure increases. This is due to the velocity of the water increasing as the pressure increases causing a lower run time. The 621 MPa is the best pressure to machine Ti-6Al-4V as it has a better MRR than the other pressures used in the predictive modelling.

scholarly journals Investigation of AlCrN-Coated Inserts on Cryogenic Turning of Ti-6Al-4V Alloy

Metals ◽  
2019 ◽  
Vol 9 (12) ◽  
pp. 1338
Author(s):  
Lakshmanan Selvam ◽  
Pradeep Kumar Murugesan ◽  
Dhananchezian Mani ◽  
Yuvaraj Natarajan
Keyword(s):  
Tool Wear ◽  
Cutting Force ◽  
Physical Vapor Deposition ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Machined Surface ◽  
Coated Carbide ◽  
Cryogenic Conditions

Over the past decade, the focus of the metal cutting industry has been on the improvement of tool life for achieving higher productivity and better finish. Researchers are attempting to reduce tool failure in several ways such as modified coating characteristics of a cutting tool, conventional coolant, cryogenic coolant, and cryogenic treated insert. In this study, a single layer coating was made on cutting carbide inserts with newly determined thickness. Coating thickness, presence of coating materials, and coated insert hardness were observed. This investigation also dealt with the effect of machining parameters on the cutting force, surface finish, and tool wear when turning Ti-6Al-4V alloy without coating and Physical Vapor Deposition (PVD)-AlCrN coated carbide cutting inserts under cryogenic conditions. The experimental results showed that AlCrN-based coated tools with cryogenic conditions developed reduced tool wear and surface roughness on the machined surface, and cutting force reductions were observed when a comparison was made with the uncoated carbide insert. The best optimal parameters of a cutting speed (Vc) of 215 m/min, feed rate (f) of 0.102 mm/rev, and depth of cut (doc) of 0.5 mm are recommended for turning titanium alloy using the multi-response TOPSIS technique.

scholarly journals Design and Development of a Three Component Milling Dynamometer

2021 ◽  
Vol 2070 (1) ◽  
pp. 012168
Author(s):  
Narender Maddela ◽  
Ch.Sai Kiran ◽  
Aluri Manoj ◽  
M. Kapila ◽  
B. Swapna ◽  
...  
Keyword(s):  
Tool Wear ◽  
Heat Generation ◽  
Strain Gauge ◽  
Cutting Forces ◽  
Metal Cutting ◽  
Strain Gauges ◽  
Tool Geometry ◽  
Work Piece ◽  
Design And Development ◽  
Machined Surface

Abstract The cutting forces that are generated during metal cutting influence the work piece precision, tool wear, the nature of the machined surface, and heat generation. These cutting forces can be measured analytically however; precise outcomes may not be expected due to its included stresses, parameters of cutting, and the perplexing tool geometry. Henceforth the exploratory estimation of cutting forces is fundamental. For this reason, a milling dynamometer of three-segment is structured, created, and tried to gauge the three cutting forces which are produced during the operation of milling strain gauges can be utilized to quantify dynamic and static cutting forces through milling dynamometer. During the process of metal cutting, a dynamometer that is based on strain gauge is fit for estimating three-force segments. The dynamometer was designed based on the octagonal ring principle. The octagonal rings orientation and location of strain gauges have resolved to expand affectability and to limit cross-affectability.

Experimental Investigation of the Machinability of Epoxy Reinforced With Graphene Platelets

2013 ◽  
Vol 135 (4) ◽  
Author(s):  
Ishank Arora ◽  
Johnson Samuel ◽  
Nikhil Koratkar
Keyword(s):  
Electron Microscopy ◽  
Tool Wear ◽  
Cutting Force ◽  
Chip Thickness ◽  
Chip Morphology ◽  
Micro Milling ◽  
Polymer Phase ◽  
Material Microstructure ◽  
Machined Surface ◽  
Transmission Electron

The objective of this research is to study the effect of graphene platelet (GPL) loading on the machinability of epoxy-based GPL composites. To this end, micro-milling experiments are conducted on composites with varying GPL content and their results are contrasted against that of plain epoxy. The material microstructure is characterized using transmission electron microscopy and scanning electron microscopy methods. Chip morphology, cutting force, machined surface morphology, and tool wear, are employed as the machinability measures for comparative purposes. At lower loadings of GPL (0.1% and 0.2% by weight), the deformation of the polymer phase plays a major role; whereas, at a higher loading of 0.3% by weight, the GPL agglomerates and interface-dominated failure dictates the machining response. The minimum chip thickness value of the composites decreases with an increase in GPL loading. Overall, the 0.2% GPL composite has the highest cutting force and the lowest tool wear.

Experimental Investigation of the Machinability of Epoxy Reinforced With Graphene Platelets

2012 ◽  
Author(s):  
Ishank Arora ◽  
Johnson Samuel ◽  
Nikhil Koratkar
Keyword(s):  
Electron Microscopy ◽  
Tool Wear ◽  
Cutting Force ◽  
Chip Thickness ◽  
Chip Morphology ◽  
Micro Milling ◽  
Polymer Phase ◽  
Material Microstructure ◽  
Machined Surface ◽  
Transmission Electron

The objective of this research is to study the effect of graphene platelet (GPL) loading on the machinability of epoxy-based GPL composites. To this end, micro-milling experiments are conducted on composites with varying GPL content and their results are contrasted against that of plain epoxy. The material microstructure is characterized using transmission electron microscopy and scanning electron microscopy methods. Chip morphology, cutting force, machined surface morphology, and tool wear, are employed as the machinability measures for comparative purposes. At lower loadings of GPL (0.1% and 0.2% by weight) the deformation of the polymer phase plays a major role, whereas at a higher loading of 0.3% by weight, the GPL agglomerates and interface-dominated failure dictates the machining response. The minimum chip thickness value of the composites decreases with an increase in GPL loading. Overall, the 0.2% GPL composite has the highest cutting force and the lowest tool wear.

Finite Element Analysis of the Effects of Tool-Chip Friction on Cutting Temperature Field

2010 ◽  
Vol 44-47 ◽  
pp. 425-429
Author(s):  
Sheng Yu Liu ◽  
Jian Ying Guo
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Friction Coefficient ◽  
Tool Wear ◽  
Inclination Angle ◽  
Metal Cutting ◽  
Cutting Temperature ◽  
Rake Angle ◽  
Element Analysis ◽  
Cutting Processes

The heat generation caused by tool-chip friction and chip deformation strongly influences the tool wear and tool life in metal cutting processes. The focus of this paper is on the effect of tool-chip on cutting temperature field. A series of ¬finite element simulations have been performed, in which a modifi¬ed Coulomb friction law is used to model the friction along tool–chip interface. A tool rake angle ranging from 10° to 45°, a inclination angle ranging from 0° to 20°, and a friction coefficient ranging from 0.1 to 0.6 have been considered in simulations. The results of these simulations show that the maximum cutting temperature increases with the increasing of tool-chip friction coefficient at different rake angle and inclination angle. The form of tool wear mainly appears as crater wear when the friction coefficient is less than 0.5, and the cutting edge tends to split when the friction coefficient is larger than 0.6.

Wavelet analysis of acoustic emission signals in boring

2000 ◽  
Vol 214 (5) ◽  
pp. 421-424 ◽  
Author(s):  
X Li ◽  
J Wu
Keyword(s):  
Acoustic Emission ◽  
Wavelet Analysis ◽  
Tool Wear ◽  
Metal Cutting ◽  
Wavelet Packet ◽  
Wavelet Packet Transform ◽  
Experimental Results ◽  
Cutting Processes ◽  
Ae Signals

Using acoustic emission (AE) signals to monitor tool wear states is one of the most effective methods used in metal cutting processes. As AE signals contain information on cutting processes, the problem of how to extract the features related to tool wear states from these signals needs to be solved. In this paper, a wavelet packet transform (WPT) method is used to decompose continuous AE signals during cutting; then the features related to tool wear states are extracted from decomposed AE signals. Experimental results verified the feasibility of using the WPT method to extract features related to tool wear states in boring.

Analytical Modelling of Temperature Distribution Using Potential Theory by Reference to Broaching of Nickel-Based Alloys

2013 ◽  
Vol 769 ◽  
pp. 139-146 ◽  
Author(s):  
Sascha Gierlings ◽  
Matthias Brockmann
Keyword(s):  
Metal Cutting ◽  
Temperature Fields ◽  
Aviation Industry ◽  
Work Piece ◽  
Machined Surface ◽  
Tool Wear Mechanisms ◽  
Critical Components ◽  
Aero Engines ◽  
Tool Centre Point ◽  
Cutting Processes

Knowledge of temperature fields and heat flow evolving during metal cutting processes is of significant importance for ensuring and predicting the product`s quality. Furthermore, this knowledge enables an improved usage of resources, such as machine tools and tool deployment. The strength of the heat sources as a result of the process and the distribution of the temperature in the material directly influence the tool wear mechanisms, wear rate, thermo-elastic deflection of the tool centre point and the amount of heat flowing into the newly generated work piece surface. Especially the latter effect is of crucial importance when it comes to safety critical components as they are employed in aero-engines. In aviation industry, the surface integrity is used as a complex quality measure summarising several aspects at the machined surface and sub-surface out of which many issues are predominantly thermal issues (e.g. temperature driven hardening of the work piece material, re-cast and white etching layers as well as residual stress profiles).

scholarly journals An Investigation of the Work Hardening Behavior in Interrupted Cutting Inconel 718 under Cryogenic Conditions

Materials ◽  
2020 ◽  
Vol 13 (9) ◽  
pp. 2202
Author(s):  
Xing Dai ◽  
Kejia Zhuang ◽  
Donglin Pu ◽  
Weiwei Zhang ◽  
Han Ding
Keyword(s):  
Work Hardening ◽  
Inconel 718 ◽  
Metal Cutting ◽  
Surface Deformation ◽  
Cutting Temperature ◽  
Service Performance ◽  
Machined Surface ◽  
Interrupted Cutting ◽  
Cutting Processes ◽  
The Given

The severe work hardening phenomenon generated in the machining of Inconel 718 is harmful to continue cutting processes, while being good for the component’s service performance. This paper investigates the performance of cryogenic assisted machining used in the cutting processes, which can reduce the waste of fluids. The influence of dry and cryogenic machining conditions with different cutting speeds on the work hardening layer is investigated based on the interrupted cutting of Inconel 718. Cutting temperature distribution obtained from simulations under different conditions is used to discuss the potential mechanism of work hardening. Then, the depth of work hardening and degree of work hardening (DWH) are investigated to analyze the surface deformation behavior, which strengthens the machined surface during metal cutting processes. From the cutting experiments, the depth of the work hardening layer can reach more than 60 μm under the given cutting conditions. In addition, a deeper zone can be obtained by the cooling of liquid nitrogen, which may potentially enhance the wear performance of the component. The results obtained from this work can be utilized to effectively control the work hardening layer beneath the surface, which can be applied to improve the service performance.

scholarly journals Partition of Primary Shear Plane Heat in Orthogonal Metal Cutting

2020 ◽  
Vol 4 (3) ◽  
pp. 82
Author(s):  
Lars Langenhorst ◽  
Jens Sölter ◽  
Sven Kuschel
Keyword(s):  
Metal Cutting ◽  
Numerical Models ◽  
Orthogonal Cutting ◽  
Chip Thickness ◽  
Shear Plane ◽  
Machining Processes ◽  
Heat Partition ◽  
Realistic Representation ◽  
Cutting Velocity ◽  
Cutting Processes

When assessing the effect of metal cutting processes on the resulting surface layer, the heat generated in the chip formation zone that is transferred into the workpiece is of major concern. Models have been developed to estimate temperature distributions in machining processes. However, most of them need information on the heat partition as input for the calculations. Based on analytical and numerical models, it is possible to determine the fraction of shear plane heat transferred into the workpiece for orthogonal cutting conditions. In the present work, these models were utilized to gain information on the significant influencing factors on heat partition, based on orthogonal cutting experiments, experimental results from the literature, and a purely model-based approach. It could be shown that the heat partition does not solely depend on the cutting velocity, the uncut chip thickness, and the thermal diffusivity—combined in the dimensionless thermal number—but the shear angle also has to be taken into account, as already proposed by some researchers. Furthermore, developed numerical models show that a more realistic representation of the process kinematics, e.g., regarding chip flow and temperature-dependent material properties, do not have a relevant impact on the heat partition. Nevertheless, the models still assume an idealized orthogonal cutting process and comparison to experimental-based findings on heat partition indicates a significant influence of the cutting edge radius and the friction on the flank face of the tool.

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