Determination of reactional cutting forces on a circular sawblade machine by using experimental studies and numerical modelling

2011 ◽  
Vol 226 (3) ◽  
pp. 775-784 ◽  
Author(s):  
N E Yasitli ◽  
F Bayram ◽  
B Unver ◽  
Y Ozcelik
Keyword(s):  
Numerical Modelling ◽  
Cutting Forces ◽  
Numerical Models ◽  
Experimental Studies ◽  
Cutting Parameters ◽  
Element Model ◽  
Natural Stone ◽  
Processing Plants ◽  
Cutting Operation ◽  
Stone Cutting

Slab/strip production from blocks in natural stone processing plants is mostly carried out by using circular sawblade cutting machines. An efficient sawing operation can only be maintained by selecting proper cutting parameters. Experimental studies and numerical modelling methods are significant in terms of identifying the effective forces occurring during natural stone cutting with circular sawblades. In this study, experimental investigation was performed on real marble, known as Afyon White Marble, using a fully automatic circular sawblade stone cutting machine. Then, numerical modelling of circular sawing was performed with commercially available software called PFC3D. A discrete-element model of the sawing process was developed, and various numerical models were performed for different peripheral speeds and advance rates in compliance with the actual cutting operation being carried out in the laboratory. Finally, data obtained from the experimental studies were compared with the modelling data. A comparison indicates that the reactional cutting forces obtained by means of the numerical modelling are in good agreement with the results of the laboratory measurements. Consequently, the cutting operation can be determined quickly and economically. A literature review showed that, through this study, numerical modelling of the circular sawblade stone cutting process was successfully performed for the first time. It was envisaged that this would dynamically help in the examination of distinct factors in the area of natural stone processing by numerical modelling and in the illustration of the sawing mechanism.

Effect of Cutting Parameters on Cutting Forces for Different Profile of Cutting

2015 ◽  
Vol 799-800 ◽  
pp. 361-365 ◽  
Author(s):  
Roshaliza Hamidon ◽  
Erry Y.T. Adesta ◽  
Muhammad Riza ◽  
Mohammad Iqbal
Keyword(s):  
Surface Finish ◽  
Orthogonal Array ◽  
Cutting Forces ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Anova Analysis ◽  
Cutting Operation ◽  
Cutting Processes ◽  
Influential Parameters ◽  
Cutting Speeds

In machining operation of mould cavities, the tool travels in various straight and corner profiles following predetermined toolpath. Such condition results in a fluctuation of cutting forces that may produce bad surface finish. The objective of this study is to investigate the most influential parameters on cutting operation for both straight and corner profiles of pocketing operation. Cutting speeds of 150, 200 and 250m/min, feedrates from 0.05, 0.1, 0.15 mm/tooth and depths of cut of 0.1, 0.15 and 0.2 mm were selected for the cutting processes. Taguchi L9 orthogonal array with Pareto ANOVA analysis was employed to analyze the effects of the selected parameters. The result demonstrates there are different effects of cutting parameters on cutting forces for straight and corner profiles. Furthermore, it was found that cutting speed and feedrate are prevailing factors that affected cutting forces for both types of profile.

scholarly journals Impact of a Single Spoiler on Scouring Depth Status Beneath a River Crossing Inclined Pipeline

2018 ◽  
Vol 8 (5) ◽  
pp. 3316-3320
Author(s):  
S. Abbasi ◽  
M. Masoomi ◽  
S. A. Arjmandi
Keyword(s):  
Numerical Models ◽  
Experimental Studies ◽  
Side Wall ◽  
Element Model ◽  
Scour Depth ◽  
Model Flow ◽  
Pipeline Management ◽  
Scouring Depth ◽  
The Impact ◽  
The Finite Element Model

Deep river crossing pipelines utilized to carry fluids are often placed upon the sand bed. Placement of pipe on the non-smooth bed would result in the production of some local gaps beneath the pipe. Asymmetric scouring is one of the main reasons for pipe underwater failures which are significant in pipeline management. So, in designing pipelines, knowing the interaction between pipelines and bed, and predicting the scour depth with respect to the pipe distance from the bed is significant to ensure that the pipe will finally deposit on the bed. Numerical models have been developed for predicting the balance depth of scouring beneath the pipelines. In this paper, the impact of pipe orientation on maximum scour depth beneath the pipelines is investigated. To do this, a pipe is modeled with various angles with the flow. To manage the local scouring, some spoilers are placed and modeled upon some pipes too. Also, in order to know the effects of placement of a pipe at various distances from the bed, the impact of placement of each pipe at a distance of 0.2D, 0.4D and 0.6D is investigated as well. To model the pipe with and without a spoiler, the finite element model Flow-3D is utilized and the results show good accordance with previous experimental studies and proof the current model’s precision in predicting the scour depth. Results show that in the placement of the pipe in angles not investigated before and also with the installing of a spoiler, the scour process has a reverse ratio with the distance which would result in full deposition of the pipe on the bed. The least scour depth belongs to the condition in which the pipe has a 130° angle with the side wall.

Numerical and Experimental Analysis of Articular Chondrocyte Deformation: Calibration of a Multiscale Finite Element Model

2007 ◽  
Author(s):  
Scott L. Bevill ◽  
Paul L. Briant ◽  
Thomas P. Andriacchi
Keyword(s):  
Finite Element ◽  
Load Transfer ◽  
Numerical Models ◽  
Experimental Studies ◽  
Element Model ◽  
Cartilage Explants ◽  
Fe Model ◽  
Articular Chondrocyte ◽  
Superficial Zone

Mechanical loading of chondrocytes in isolation [1] and of articular cartilage in culture [2] has been reported to be a potent regulator of chondrocyte metabolism. Experimental studies have related tissue-level and cell-level strains in mechanically loaded cartilage explants [3], but cannot be readily extended to address more physiologic loading cases. Numerical models, which might address this need, have primarily been axisymmetric [4, 5] or two-dimensional [6] and have idealized chondrocyte geometry. Given the complexity of the mechanism of the load transfer between the tissue and cell, however, there remains a lack of information regarding the in vivo level of cell stresses and strains. Thus, the purpose of this study was to develop a multiscale experimental/numerical approach to calibrate a three-dimensional finite element (FE) model of a chondrocyte based on experimentally derived chondrocyte morphology and deformation data. The method was than applied to determine the modulus of a chondrocyte located in the superficial zone.

Influence of Rock Mechanical Properties on the Formation of Rock Fragments During Cutting Operation

2011 ◽  
Author(s):  
Pradeep L. Menezes ◽  
Michael R. Lovell
Keyword(s):  
Mechanical Properties ◽  
Cutting Forces ◽  
Numerical Models ◽  
Cutting Parameters ◽  
Rock Cutting ◽  
Rake Angle ◽  
Rock Fragmentation ◽  
Oil Well ◽  
Explicit Finite Element ◽  
Rock Mechanical Properties

Mechanical rock cutting is a process encountered in different engineering applications including rock excavation, mining and deep oil well drilling. Rock mechanical properties vary with depth in the subsurface and also at different geographical locations due to different environmental conditions. Understanding of fragmentation mechanisms in specific rock materials allows the determination of optimum cutting parameters that improve cutting efficiency and increase tool life during cutting operations. In the present investigation, numerical models that accurately predict the rock fragmentation and stress profiles in the rock slab during cutting were developed using the explicit finite-element method (FEM). In the numerical models, a damage material model was utilized to capture the rock fragmentation process and a rigid steel cutter (at different rake angles) was displaced at different velocities against a stationary rock slab. Rock slabs with significantly different mechanical properties were incorporated with a constant friction factor and a cutting depth of 1 mm. The variation of cutting forces and stresses, and fragmentation of the rock slab were analyzed. The simulation results indicated that the explicit FEM is a powerful tool for simulating rock cutting as the formation of fragments were distinctly observed at different cutting conditions. The rock mechanical properties and tool rake angle were found to have the most significant effect on the rock fragmentation during cutting operations. The cutting forces were also influenced by mechanical properties of the rock and tool rake angle.

On Methodologies inside Two Different Commercial Codes to Simulate the Cutting Operation

2011 ◽  
Vol 223 ◽  
pp. 162-171
Author(s):  
Yan Cheng Zhang ◽  
Domenico Umbrello ◽  
Tarek Mabrouki ◽  
Stefania Rizzuti ◽  
Daniel Nelias ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Titanium Alloy ◽  
Surface Integrity ◽  
Chip Formation ◽  
Cutting Forces ◽  
Orthogonal Cutting ◽  
Cutting Parameters ◽  
Cutting Operation ◽  
Cutting Processes ◽  
Cutting Model

Nowadays, numerical simulation of cutting processes receives considerable interest among the scientific and industrial communities. For that, various numerical codes are used. Nevertheless, there is no uniform standard for the comparison of simulation model with these different software. So, it is often not easy to state if a given code is more pertinent than another. In this framework, the present work deals with various methodologies to simulate orthogonal cutting operation inside two commercial codes Abaqus and Deform. The aim of the present paper is to build a common benchmark model between the two pre-cited codes which can initiate other numerical cutting model comparisons. The study is focused on the typical aeronautical material - Ti-6Al-4V - Titanium alloy. In order to carry out a comparative study between the two codes, some similar conditions concerning geometrical models and cutting parameters were respected. A multi-physic comprehension related to chip formation, cutting forces and temperature evolutions, and surface integrity is presented. Moreover, the numerical results are compared with experimental ones.

Ultrasonic-Vibration Hard Cutting Force Analysis with the Finite Element Method

2010 ◽  
Vol 455 ◽  
pp. 360-364 ◽  
Author(s):  
Jing Lin Tong ◽  
Yan Yan Yan ◽  
Bo Zhao
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Ultrasonic Vibration ◽  
Cutting Forces ◽  
Cutting Tool ◽  
Cutting Speed ◽  
Cutting Parameters ◽  
Element Model ◽  
Advanced Technology ◽  
Hard Cutting

Ultrasonic-vibration hard cutting (UVHC) is a advanced technology, where high- frequency vibration is superimposed on the movement of the cutting tool. Compared to conventional turning (CT), this technique allows significant improvements in processing hard-to-cut materials, by producing a noticeable decrease in cutting forces and a superior surface finish. The paper presents a finite-element model of both CT and UVHC. Stresses produced in workpiece and cutting forces acting on the cutting tool in UVHC are studied, and the influence of cutting parameters, such as cutting speed and cutting depth on cutting force are investigated.

Validation of Numerical Models Used for Designing the Composite Blade for ILX-27 Rotorcraft

2019 ◽  
Vol 2019 (4) ◽  
pp. 23-31
Author(s):  
Jakub Wilk ◽  
Radosław Guzikowski
Keyword(s):  
Epoxy Composite ◽  
Numerical Models ◽  
Experimental Studies ◽  
Strength Analysis ◽  
Laminate Glass ◽  
Composite Blade ◽  
Real Objects ◽  
Validation Procedure ◽  
Research Objects ◽  
Comparison Of The Results

Abstract The paper presents the validation procedure of the model used in the analysis of the composite blade for the rotor of the ILX-27 rotorcraft, designed and manufactured in the Institute of Aviation, by means of numerical analyses and tests of composite elements. Numerical analysis using finite element method and experimental studies of three research objects made of basic materials comprising the blade structure – carbon-epoxy laminate, glass-epoxy composite made of roving and foam filler – were carried out. The elements were in the form of four-point bent beams, and for comparison of the results the deflection arrow values in the middle of the beam and axial deformations on the upper and lower surfaces were selected. The procedure allowed to adjust the discrete model to real objects and to verify and correct the material data used in the strength analysis of the designed blade.

scholarly journals Experimental and Numerical Investigation on the Perforation Resistance of Double-Layered Metal Shield under High-Velocity Impact of Armor-Piercing Projectiles

Materials ◽  
2021 ◽  
Vol 14 (3) ◽  
pp. 626
Author(s):  
Riccardo Scazzosi ◽  
Marco Giglio ◽  
Andrea Manes
Keyword(s):  
High Strength Steel ◽  
Steel Plate ◽  
Experimental Studies ◽  
Practical Interest ◽  
High Strength ◽  
Experimental Tests ◽  
Element Model ◽  
Transportation Systems ◽  
Metal Shield ◽  
Softening Parameter

In the case of protection of transportation systems, the optimization of the shield is of practical interest to reduce the weight of such components and thus increase the payload or reduce the fuel consumption. As far as metal shields are concerned, some investigations based on numerical simulations showed that a multi-layered configuration made of layers of different metals could be a promising solution to reduce the weight of the shield. However, only a few experimental studies on this subject are available. The aim of this study is therefore to discuss whether or not a monolithic shield can be substituted by a double-layered configuration manufactured from two different metals and if such a configuration can guarantee the same perforation resistance at a lower weight. In order to answer this question, the performance of a ballistic shield constituted of a layer of high-strength steel and a layer of an aluminum alloy impacted by an armor piercing projectile was investigated in experimental tests. Furthermore, an axisymmetric finite element model was developed. The effect of the strain rate hardening parameter C and the thermal softening parameter m of the Johnson–Cook constitutive model was investigated. The numerical model was used to understand the perforation process and the energy dissipation mechanism inside the target. It was found that if the high-strength steel plate is used as a front layer, the specific ballistic energy increases by 54% with respect to the monolithic high-strength steel plate. On the other hand, the specific ballistic energy decreases if the aluminum plate is used as the front layer.

scholarly journals A surrogate-assisted optimization approach for multi-response end milling of aluminum alloy AA3105

2020 ◽  
Vol 111 (9-10) ◽  
pp. 2419-2439
Author(s):  
Tamal Ghosh ◽  
Yi Wang ◽  
Kristian Martinsen ◽  
Kesheng Wang
Keyword(s):  
Surface Roughness ◽  
Aluminum Alloy ◽  
Material Removal Rate ◽  
Cutting Forces ◽  
Material Removal ◽  
End Milling ◽  
Removal Rate ◽  
Cutting Parameters ◽  
Data Driven ◽  
Optimal Cutting Parameters

Abstract Optimization of the end milling process is a combinatorial task due to the involvement of a large number of process variables and performance characteristics. Process-specific numerical models or mathematical functions are required for the evaluation of parametric combinations in order to improve the quality of the machined parts and machining time. This problem could be categorized as the offline data-driven optimization problem. For such problems, the surrogate or predictive models are useful, which could be employed to approximate the objective functions for the optimization algorithms. This paper presents a data-driven surrogate-assisted optimizer to model the end mill cutting of aluminum alloy on a desktop milling machine. To facilitate that, material removal rate (MRR), surface roughness (Ra), and cutting forces are considered as the functions of tool diameter, spindle speed, feed rate, and depth of cut. The principal methodology is developed using a Bayesian regularized neural network (surrogate) and a beetle antennae search algorithm (optimizer) to perform the process optimization. The relationships among the process responses are studied using Kohonen’s self-organizing map. The proposed methodology is successfully compared with three different optimization techniques and shown to outperform them with improvements of 40.98% for MRR and 10.56% for Ra. The proposed surrogate-assisted optimization method is prompt and efficient in handling the offline machining data. Finally, the validation has been done using the experimental end milling cutting carried out on aluminum alloy to measure the surface roughness, material removal rate, and cutting forces using dynamometer for the optimal cutting parameters on desktop milling center. From the estimated surface roughness value of 0.4651 μm, the optimal cutting parameters have given a maximum material removal rate of 44.027 mm3/s with less amplitude of cutting force on the workpiece. The obtained test results show that more optimal surface quality and material removal can be achieved with the optimal set of parameters.

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