scholarly journals Study of Parameters during Aluminum Cutting with Finite Element Method

2020 ◽  
Vol 64 (2) ◽  
pp. 136-144
Author(s):  
János György Bátorfi ◽  
Mátyás Andó
Keyword(s):  
Finite Element ◽  
Shear Plane ◽  
Material Model ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Finite Element Software ◽  
Cutting Velocity ◽  
Deform 2D ◽  
Cutting Model

The authors analyzed the force and stress values in the simplified cutting model and compared the results with the literature. For the study a 2D model was created in DEFORM 2D finite element software, using the temperature depended multilinear flow stress material model. The model was compiled according to the literatures. In this analysis were the effects of relief angel, tool angle, tool radius, depth of cut, and the cutting velocity examined. The values of forces, strain, temperature, stress and shear plane angle were examined at different values of geometry and machining parameters. For these examinations were used 28 parameter combinations. As a result of the study, the results for forces are similar to the results of examined literature at every parameter. The force results were checked on a simple tool geometry.

Study on Residual Stress in High-Speed Cutting NAK80 Mold-Steel

2012 ◽  
Vol 217-219 ◽  
pp. 458-462
Author(s):  
Jian Xin Pan ◽  
Zhi Xiong Zhou
Keyword(s):  
Residual Stress ◽  
Finite Element ◽  
High Speed ◽  
Orthogonal Cutting ◽  
Tool Geometry ◽  
Stress Distributions ◽  
High Speed Cutting ◽  
Finite Element Software ◽  
Cutting Model ◽  
Cutting Speeds

An orthogonal cutting model was presented，and the cutting process was simulated by a finite element software based on the thermal-elastic-plastic FEM theory and updated Lagrange method.We obtained the distributions of residual stresses in machined layer of NAK80 mold-steel.The effects of cutting speeds，cutting depths and tool geometry on residual stress distributions were investigated. Comparing to experimental results，the conclusions are more accurate.

scholarly journals An Investigation of the Cutting Strategy for the Machining of Polar Microstructures Used in Ultra-Precision Machining Optical Precision Measurement

Micromachines ◽  
2021 ◽  
Vol 12 (7) ◽  
pp. 755
Author(s):  
Chen-Yang Zhao ◽  
Chi-Fai Cheung ◽  
Wen-Peng Fu
Keyword(s):  
Precision Measurement ◽  
Detection Algorithm ◽  
Surface Generation ◽  
Precision Machining ◽  
Tool Geometry ◽  
Depth Of Cut ◽  
Machining Parameters ◽  
Ultra Precision ◽  
Transition Points ◽  
Cutting Strategy

In this paper, an investigation of cutting strategy is presented for the optimization of machining parameters in the ultra-precision machining of polar microstructures, which are used for optical precision measurement. The critical machining parameters affecting the surface generation and surface quality in the machining of polar microstructures are studied. Hence, the critical ranges of machining parameters have been determined through a series of cutting simulations, as well as cutting experiments. First of all, the influence of field of view (FOV) is investigated. After that, theoretical modeling of polar microstructures is built to generate the simulated surface topography of polar microstructures. A feature point detection algorithm is built for image processing of polar microstructures. Hence, an experimental investigation of the influence of cutting tool geometry, depth of cut, and groove spacing of polar microstructures was conducted. There are transition points from which the patterns of surface generation of polar microstructures vary with the machining parameters. The optimization of machining parameters and determination of the optimized cutting strategy are undertaken in the ultra-precision machining of polar microstructures.

scholarly journals Numerical simulation of blanking process

2018 ◽  
Vol 157 ◽  
pp. 02038
Author(s):  
Peter Pecháč ◽  
Milan Sága
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Steel Sheet ◽  
Plastic Material ◽  
Material Model ◽  
Rolled Steel ◽  
Finite Element Software ◽  
History Of ◽  
Cold Rolled ◽  
Blanking Process

This paper presents numerical simulation of blanking process for cold-rolled steel sheet metal. The problem was modeled using axial symmetry in commercial finite element software ADINA. Data obtained by experimental measurement were used to create multi-linear plastic material model for simulation. History of blanking force vs. tool displacement was obtained.

scholarly journals A Phenomenological Mechanical Material Model for Precipitation Hardening Aluminium Alloys

Metals ◽  
2019 ◽  
Vol 9 (11) ◽  
pp. 1165 ◽  
Author(s):  
Hannes Fröck ◽  
Lukas Vincent Kappis ◽  
Michael Reich ◽  
Olaf Kessler
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Finite Element ◽  
Phase Transformation ◽  
Aluminium Alloys ◽  
Material Model ◽  
Heat Treatments ◽  
Maximum Temperature ◽  
Finite Element Software ◽  
Welding Processes

Age hardening aluminium alloys obtain their strength by forming precipitates. This precipitation-hardened state is often the initial condition for short-term heat treatments, like welding processes or local laser heat treatment to produce tailored heat-treated profiles (THTP). During these heat treatments, the strength-increasing precipitates are dissolved depending on the maximum temperature and the material is softened in these areas. Depending on the temperature path, the mechanical properties differ between heating and cooling at the same temperature. To model this behavior, a phenomenological material model was developed based on the dissolution characteristics and experimental flow curves were developed depending on the current temperature and the maximum temperature. The dissolution characteristics were analyzed by calorimetry. The mechanical properties at different temperatures and peak temperatures were recorded by thermomechanical analysis. The usual phase transformation equations in the Finite Element Method (FEM) code, which were developed for phase transformation in steels, were used to develop a phenomenological model for the mechanical properties as a function of the relevant heat treatment parameters. This material model was implemented for aluminium alloy 6060 T4 in the finite element software LS-DYNA (Livermore Software Technology Corporation).

Finite Element Modeling of Orthogonal Cutting of Pyrolytic Carbon

2011 ◽  
Author(s):  
Gautam Salhotra ◽  
Vivek Bajpai ◽  
Ramesh K. Singh
Keyword(s):  
Finite Element ◽  
Transverse Isotropy ◽  
Orthogonal Cutting ◽  
Chip Morphology ◽  
Pyrolytic Carbon ◽  
Cutting Conditions ◽  
Prediction Errors ◽  
Machining Parameters ◽  
Machined Surface ◽  
Cutting Model

Engineered features on pyrolytic carbon (PyC) have been demonstrated as an approach to improve the flow hemodynamics of the cardiovascular implants. In addition, it also finds application in thermonuclear components. These micro/meso scale engineered features are required to be machined onto the PyC leaflet. However, being a layered anisotropic material and brittle in nature, its machining characteristics differ from plastically deformable isotropic materials. Consequently, this study is aimed at creating a finite element model to understand the mechanics of material removal in the plane of transverse isotropy (horizontally stacked laminae) of PyC. A layered model approach has been used to capture the interlaminar shearing and brittle fracture during machining. A cohesive element layer has been used between the chip layer and the machined surface layer. The chip layer and workpiece are connected through a cohesive layer. The model predicts cutting forces and the chip length for different cutting conditions. The orthogonal cutting model has been validated against experimental data for different cutting conditions for cutting and thrust forces. Parametric studies have also been performed to understand effect of machining parameters on machining responses. This model also predicts chip lengths which have also been compared with the actual chip morphology obtained from microgrooving experiments. The prediction errors for cutting force and chip length are within 20% and 33%, respectively.

scholarly journals Hot Workability of Ultra-Supercritical Rotor Steel Using a 3-D Processing Map Based on the Dynamic Material Model

Materials ◽  
2020 ◽  
Vol 13 (18) ◽  
pp. 4118
Author(s):  
Xuewen Chen ◽  
Yuqing Du ◽  
Tingting Lian ◽  
Kexue Du ◽  
Tao Huang
Keyword(s):  
Finite Element ◽  
Alloy Steel ◽  
Thermal Processing ◽  
Processing Map ◽  
Three Dimensional ◽  
Material Model ◽  
Strain Rates ◽  
Rotor Steel ◽  
Dynamic Material Model ◽  
Finite Element Software

As a new-type of ultra-supercritical HI-IP rotor steel, X12CrMoWVNbN10-1-1 alloy steel has excellent integrative performance, which can effectively improve the power generation efficiency of the generator set. In this paper, uniaxial thermal compression tests were carried out over a temperature range of 950–1200 °C and strain rates of 0.05–5 s−1 with a Gleeble-1500D thermal simulation testing machine. Moreover, based on hot compression experimental data and the theory of processing diagrams, in combination with the dynamic material model, a three-dimensional (3-D) thermal processing map considering the effect of strain was constructed. It was concluded that optimum thermal deformation conditions were as follows: the temperature range of 1150–1200 °C, the strain rate range of 0.05–0.634 s−1. Through secondary development of the finite element (FE) software FORGE®, three-dimensional thermal processing map data were integrated into finite element software FORGE®. The distributions of instability coefficient and power dissipation coefficient were obtained over various strain rates and temperatures of the Ø 8 × 12 mm cylinder specimen by using finite element simulation. It is shown that simulation results are consistent with the microstructure photos. The method proposed in this paper, which integrates the three-dimensional processing map into the finite element software FORGE® (Forge NxT 2.1, Transvalor, Nice, France), can effectively predict the formability of X12CrMoWVNbN10-1-1 alloy steel.

Development of Constitutive Equation for Infinite Body of Impact Problem

2007 ◽  
Vol 353-358 ◽  
pp. 611-614
Author(s):  
Seung Yong Yang
Keyword(s):  
Finite Element ◽  
Constitutive Equation ◽  
Plane Waves ◽  
Shear Plane ◽  
Material Behavior ◽  
Infinite Body ◽  
Wave Impact ◽  
Finite Element Software ◽  
Impact Simulations ◽  
Impact Problem

A constitutive equation was developed for an infinite body in plane wave impact problem, and implemented using the finite element software ABAQUS user subroutine. Bilinear material behavior under monotonically increasing loading was considered for the constitutive equation. The finite element governed by this type of material behavior can be used as an infinite body transmitting longitudinal and shear plane waves, so that the number of finite elements can be reduced in impact simulations. To test the developed method, results of a plate impact experiment were examined. The numerical results show the accuracy of the developed constitutive equation.

Finite Element Analysis of Burr Formation in Micro-Machining

2014 ◽  
Vol 487 ◽  
pp. 225-229
Author(s):  
Juan Huang ◽  
Yong Hua Xiong ◽  
Jin Gui Huang ◽  
Gui Cheng Wang
Keyword(s):  
Finite Element ◽  
High Surface ◽  
Cutting Parameters ◽  
Burr Formation ◽  
Contact Friction ◽  
Tool Geometry ◽  
Work Piece ◽  
Micro Cutting ◽  
Finite Element Software ◽  
General Law

In the process of micro-cutting for the precision small parts, one of the main problems is the micro burrs. The finite element software Abaqus was used to simulate the micro-cutting process of aluminum 2024-T3. To create this model, Johnson-Cook (J-C) model was used to establish the material model, and Arbitrary Lagrangian Eulerian (ALE) method was used to separate the chip from work-piece. The contact friction models which was used between chip and tool was the modified Coulomb friction law. The formation process of micro burrs was simulated dynamically, and the effect of different cutting parameters and tool geometry parameters on burrs forming was analyzed. Furthermore, the general law was obtained. The results provide the guidance for optimizing the tool geometry parameters and cutting parameters to reduce the burrs in micro-cutting with the high surface quality.

Cutting Model in Machining of Al/SiCp Metal Matrix Composite

2011 ◽  
Vol 410 ◽  
pp. 291-297
Author(s):  
Sayed Mohamad Nikouei ◽  
R. Yousefi ◽  
Mohammad Ali Kouchakzadeh ◽  
M.A. Kadivar
Keyword(s):  
Chip Formation ◽  
Cutting Forces ◽  
Metal Matrix ◽  
Cutting Speed ◽  
Shear Plane ◽  
Good Method ◽  
Depth Of Cut ◽  
Machining Forces ◽  
Experimental Cutting ◽  
Cutting Model

Prediction of shear plane angle is a way for prediction of the mechanism of chip formation, machining forces and so on. In this study, Merchant and Lee-Shaffer theories are used for prediction of shear plane angles and cutting forces in machining of Al/SiCpMMC with 20% of SiC as reinforcement particles. The experimental cutting forces are compared with the calculated cutting force based on shear plane angles extracted from Merchant and Lee-Shaffer theories. The variation of these cutting forces with cutting speed, feed rate and depth of cut has been discussed. The results showed that Merchant theory may be used as a good method for prediction of chip formation in machining of Al/SiCpMMC.

scholarly journals Numerical Investigation of Tool Parameters Influence on the Interlock Forming During Flat Clinching Process

2021 ◽  
Author(s):  
Zhiyong Wang ◽  
Shanling Han ◽  
Zhiyong Li ◽  
Yong Li
Keyword(s):  
Finite Element ◽  
Numerical Model ◽  
Linear Relationship ◽  
Numerical Investigation ◽  
Vital Role ◽  
Blank Holder ◽  
Finite Element Software ◽  
Punch Radius ◽  
Deform 2D ◽  
The Relationship

Abstract Tool parameters play a vital role in the mechanical interlock formation during the flat clinching process, to understand the influence of tool parameters on the interlock formation, the finite element software DEFORM-2D was used to build the numerical model of the flat clinching process, and the numerical model was verified by the experiment. The influences of the punch radius, punch fillet radius, and blank holder radius on the interlock formation of the clinched joint were investigated using the numerical model. Then, the relationship between the punch radius and blank holder radius was studied. The results showed that the interlock gradually increases with the increase of the blank holder radius, after that, the interlock begins to decrease. To maximize the interlock, the punch radius and the blank holder radius should be increased simultaneously. It can be concluded that the blank holder radius and the punch radius should keep in a linear relationship when designing the geometric dimensions of the flat clinch tools, which can promote the application of flat clinching process in car body manufacturing.

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