scholarly journals ANALYSIS OF THERMAL PHENOMENA IN MILLING PROCESS

2019 ◽  
Vol 34 (3) ◽  
pp. 621-627
Author(s):  
Anđelija Mitrović ◽  
Maja Radović
Keyword(s):  
Finite Element ◽  
Software Package ◽  
Cutting Temperature ◽  
Milling Process ◽  
Cutting Process ◽  
Temperature Fields ◽  
Complex Geometries ◽  
The Finite Element Method ◽  
Mathematical Simulations ◽  
Cutting Zone

Milling is one of the most conventional machining processes used in the industry. The cutting edge of the mill tooth periodically enters and exits from the contact with the workpiece, which leads to periodic heating and cooling during machining. This process is influenced by many output parameters and one of the most important parameters is the temperature because it affects the tool wear and tool life. Also, during the milling process the cross-section of the chip is variable. Cutting tools are expensive and have a duration that is measured in minutes and therefore, predicting temperature and tool wear during the machining process is of the great importance for the understanding and optimization of process parameters. To determine cutting temperature or temperature fields in end milling different methods can be used. During the last decades various experimental methods were developed for measuring cutting temperature. Measuring temperature with infrared thermal imaging camera is most suitable method concerning capturing values of temperature fields. An experimental approach to studying the cutting process is expensive and time-consuming, especially when a wide range of tool geometry, material, and machining parameters are included. Because of these difficulties, alternative approaches such as mathematical simulations have been developed. Numerical methods are most commonly used in those mathematical simulations. In the research field of cutting process, the finite element method is regarded as a very useful tool to study the cutting process of materials. The aim of this paper is the modeling and simulation of milling predictive temperature in the cutting zone by using the finite element method. The right choice of finite element software is very important in determining the scope and quality of the analysis that will be performed. In order to predict the occurrence of thermal processing milling was used software package Third Wave AdvantEdge. AdvantEdge contains a user-friendly interface and offers the possibility of creating new tool and workpiece geometries within the program and also to import complex geometries form other CAD files. 3D model of the workpiece and end mill was created in the software package SolidWorks. AdvantEdge also allows users to import complex geometries and have extensive material library and allows specifying new materials uses adaptive meshing to increase the accuracy of solution. Workpiece material AISI 4340 steel and tool material Carbide-General were selected from the library of 3D materials. For proper cutting conditions we have presented the results of simulation-based on which the influence of feed per tooth on the temperature in the cutting zone is analyzed.

Study on Milling Process Based on Finite Element Analysis

2012 ◽  
Vol 468-471 ◽  
pp. 1322-1325
Author(s):  
Yong Liang Zhang ◽  
Rui Jie Wang ◽  
Hong Bin Liu ◽  
Mao Hua Du ◽  
Xiao Dong Xu
Keyword(s):  
Finite Element Analysis ◽  
Finite Element ◽  
High Speed ◽  
Cutting Temperature ◽  
Milling Process ◽  
Cutting Process ◽  
Feed Speed ◽  
Element Analysis ◽  
High Speed Cutting ◽  
Deformation Force

The influence of negative chamfers of PCBN milling cutters on cutting process of high speed cutting is studied based on finite element analysis. The milling speed, axial cutting depth and feed speed are all set fixed, while the negative chamfer angle varies. Cutting tool stress, deformation force, and cutting temperature are obtained for cutting process under different negative chamfering Angle,thus providing basis for the selection of tool parameters in practical production.

scholarly journals T3D end milling finite element thermal analysis

2018 ◽  
Vol 184 ◽  
pp. 03001
Author(s):  
Andjelija. Mitrović ◽  
Pavel. Kovač ◽  
Nenad. Kulundžić ◽  
Borislav. Savković ◽  
Ildiko. Mankova
Keyword(s):  
Thermal Analysis ◽  
Finite Element ◽  
Software Package ◽  
End Milling ◽  
Cutting Speed ◽  
Milling Process ◽  
Work Piece ◽  
Third Wave ◽  
Modern Approach ◽  
Cutting Zone

The paper presents a modern approach to the phenomenon of thermal analysis in end milling by the finite element method. 3D model of the end mill and work-piece was created in the software package SolidWorks. In order to predict the occurrence of thermal phenomena in milling process software package Third Wave AdvatEdge was used. Influence of cutting speed on the temperature in cutting zone was modelled and analyzed.

Predicting the High Speed Cutting Process of Titanium Alloy by Finite Element Method

2011 ◽  
Author(s):  
Xiangqin Zhang ◽  
Xueping Zhang ◽  
A. K. Srivastava
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
High Speed ◽  
Cutting Temperature ◽  
Chip Morphology ◽  
Cutting Process ◽  
Fe Model ◽  
Dry Cutting ◽  
Friction Coefficients ◽  
Machining Conditions

To predict the cutting forces and cutting temperatures accurately in high speed dry cutting Ti-6Al-4V alloy, a Finite Element (FE) model is established based on ABAQUS. The tool-chip-work friction coefficients are calculated analytically using the measured cutting forces and chip morphology parameter obtained by conducting the orthogonal (2-D) machining tests. It reveals that the friction coefficients between tool-work are 3∼7 times larger than that between tool-chip, and the friction coefficients of tool-chip-work vary with feed rates. The analysis provides a better reference for the tool-work-chip friction coefficients than that given by literature empirically regardless of machining conditions. The FE model is capable of effectively simulating the high speed dry cutting process of Ti-6Al-4V alloy based on the modified Johnson-Cook model and tool-work-chip friction coefficients obtained analytically. The FE model is further validated in terms of predicted forces and the chip morphology. The predicted cutting force, thrust force and resultant force by the FE model agree well with the experimentally measured forces. The errors in terms of the predicted average value of chip pitch and the distance between chip valley and chip peak are smaller. The FE model further predicts the cutting temperature and residual stresses during high speed dry cutting of Ti-6Al-4V alloy. The maximum tool temperatures exist along the round tool edge, and the residual stress profiles along the machined surface are hook-shaped regardless of machining conditions.

Study on the Cutting Temperature and Chips Formation during the Milling of Pure Titanium

2018 ◽  
Vol 880 ◽  
pp. 315-320
Author(s):  
Emil Nicusor Patru ◽  
Dumitru Panduru ◽  
Nicolae Craciunoiu ◽  
Marin Bica
Keyword(s):  
Pure Titanium ◽  
Cutting Temperature ◽  
Milling Process ◽  
Cutting Conditions ◽  
Cutting Process ◽  
Screen Capture

In this paper some experimental determinations on the temperature during the milling process of pure titanium is conducted, using different cutting conditions. The results are presented as graphical dependencies and also as a screen capture of the values obtained using an adequate technique for temperature of the cutting process. Some pictures of the chips shape captured during milling process of the pure titanium bare are presented.

Improving the honing accuracy of the holes of stepped thin-walled cylinders

2021 ◽  
pp. 49-54
Author(s):  
V.A. Ogorodov
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Cutting Forces ◽  
Software Package ◽  
The Finite Element Method ◽  
Radial Forces ◽  
Thin Walled ◽  
Hole Machining ◽  
Deform 3D ◽  
Walled Cylinder

Different ways of fixing of stepped thin-walled cylinders during honing are analyzed. The conditions for increasing the accuracy of hole machining are determined on the basis of unevenness of cylinder deformations from clamping forces and radial forces simulating cutting forces. The studies used the finite element method and the DEFORM-3D V6.1 software package. Keywords: honing, stepped thin-walled cylinder, hole, accuracy, fixing method, deformation, unevenness, DEFORM-3D V6.1 software package. [email protected]

scholarly journals Calculation of radial inhomogeneity cylindrical shell when exposed to high temperatures by numerical-analytical method and fem

2019 ◽  
Vol 135 ◽  
pp. 01037
Author(s):  
Vladimir Andreev ◽  
Lyudmila Polyakova
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Analytical Method ◽  
Software Package ◽  
Successive Approximations ◽  
Method Of Successive Approximations ◽  
Infinite Cylinder ◽  
The Finite Element Method ◽  
Numerical Analytical Method ◽  
Element Method

The purpose of the work is to compare two calculation methods using the example of solving the axisymmetric thermoelasticity problem. The calculation of a thick-walled cylindrical three-layer shell on the temperature effect was carried out by the numerical-analytical method and the finite element method implemented in the LIRA-CAD software package. In the calculation, a piecewise linear inhomogeneity of the shell due to its three-layer structure and continuous inhomogeneity caused by the influence of a stationary temperature field is taken into account. The numerical-analytical method of calculation involves the derivation of a resolving differential equation, which is solved by the sweep method, it is possible to take into account the nonlinear nature of the deformation of the material using the method of successive approximations. To solve this problem by the finite element method, a similar computational model of the shell was constructed in the LIRA-CAD software package. The solution of the problem of thermoelasticity for an infinite cylinder (under conditions of a plane deformed state) and for a cylinder of finite length with free ends is given. Comparison of the calculation results is carried out according to the obtained values of ring stresses.

Seepage and Heat Flow in Soil Freezing

1982 ◽  
Vol 104 (2) ◽  
pp. 323-328 ◽  
Author(s):  
P. E. Frivik ◽  
G. Comini
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Seepage Flow ◽  
Soil Freezing ◽  
Temperature Fields ◽  
Laboratory Model ◽  
Experimental Measurements ◽  
The Finite Element Method ◽  
Freezing And Thawing ◽  
Velocity And Temperature Fields

In this paper we describe a system of computer programs based on the finite element method, which can be used for the calculation of coupled velocity and temperature fields during freezing and thawing of soils in the presence of seepage flow. In the programs, the mass and energy conservation equations are solved simultaneously, without the use of too limiting assumptions. The results of the computations are compared with experimental measurements made on a laboratory model of a soil freezing system, and the agreement between measured and computed values is good.

scholarly journals Features of compressed rods calculations with account of initial imperfections and creep effects

2020 ◽  
Vol 164 ◽  
pp. 02003
Author(s):  
Viacheslav Chepurnenko ◽  
Batyr Yazyev ◽  
Ludmila Dubovitskaya
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Software Package ◽  
Physical Nonlinearity ◽  
The Finite Element Method ◽  
Ansys Software ◽  
Modular Theory ◽  
Initial Imperfections ◽  
Creep Models ◽  
The Finite Difference Method

The article presents solutions to the problem of rod buckling, taking into account creep effects. Trigonometric series, the finite difference method in combination with the programming language MATLAB, as well as the finite element method in the ANSYS software package were used in the solutions. The behavior of the rods is researched for two types of relations between strain and stress during creep, with strains in an explicit and implicit form. When solving, the criterion of initial imperfections with their different values is used, as well as the tangential-modular theory. The results obtained for the two creep models are compared. The conclusion is made about the accuracy of the results of calculations in ANSYS with the presence of a combination of geometric and physical nonlinearity for various creep models.

Measurement and Modeling of Heat Partitions and Temperature Fields in the Workpiece for Cutting Inconel 718, AISI 1045, Ti6Al4V, and AlMgSi0.5

2019 ◽  
Vol 141 (6) ◽  
Author(s):  
Thorsten Augspurger ◽  
Thomas Bergs ◽  
Benjamin Döbbeler
Keyword(s):  
Heat Flow ◽  
Peclet Number ◽  
Inconel 718 ◽  
Flow Distribution ◽  
Milling Process ◽  
Cutting Process ◽  
Evaluation Criterion ◽  
Temperature Fields ◽  
Péclet Number ◽  
Aisi 1045

The quantification of the heat flow distribution in the metal cutting process depending on the cut material and the process parameters is a research area with a long history. However, a quantification of the heat flow distribution between chip, tool, and workpiece is still a not fully solved problem and remains a necessary input value for the further modeling of temperature fields and subsequent tool wear and thermal induced surface alterations, which may impair the workpiece functionality. Thus, the following publication shows the results of orthogonal cutting in order to investigate the heat flow distribution between the chip and workpiece. Therefore, the heat partitions in the cutting process were calculated by a thermodynamic methodology. This methodology considers the temperature rise in the workpiece and the chip, measured by thermography and pyrometry, as the effect of the cutting work dissipated into sensible heat. Four metals, Inconel 718, AISI 1045, Ti6Al4V, and AlMgSi0.5, were cut at varying undeformed chip thicknesses and cutting velocities. By formulating a dimensionless number for the cutting process, the Péclet number, the thermal diffusivity was included as an evaluation criterion of heat partitioning between the chip and workpiece across material properties and process settings. In this way, the validity of the Péclet number as an evaluation criterion for heat partitions in cutting and as a valuable heuristic for process design was confirmed. Another goal was to extend the state of the art approach of empirical process analysis by orthogonal cuts with regard to specific cutting forces into the thermal domain in order to provide the basis for further temperature modeling in cutting processes. The usage of the empirical data basis was finally demonstrated for the analytical modeling of temperature fields in the workpiece during milling. Therefore, the specific heat inputs into the workpiece measured in the orthogonal cuts were transferred to the milling process kinematics in order to model the heat flow into the workpiece during milling. This heat flow was used as input for an existing analytical model in order to predict stationary temperature fields in the milling process for the two-dimensional case.

Finite Element Simulation on High Speed Cutting of Hardened 45 Steel Based on ABAQUS

2013 ◽  
Vol 579-580 ◽  
pp. 202-207
Author(s):  
Guo He Li ◽  
Hou Jun Qi ◽  
Bing Yan
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Finite Element Simulation ◽  
High Speed ◽  
Cutting Temperature ◽  
Cutting Parameters ◽  
Cutting Process ◽  
High Speed Cutting ◽  
Geometry Model ◽  
Element Simulation

For the high speed cutting process of hardened 45 steel (45HRC), a finite element simulation of cutting deformation, cutting force and cutting temperature is finished with the large general finite element software ABAQUS. Through the building of geometry model, material model and heat conduction model, also the determination of boundary conditions, separation rule and friction condition, a thermal mechanical coupling finite element model of high speed cutting for hardened 45 steel is built. The serrated chip, cutting force and cutting temperature can be predicted. The comparison of experiment and simulation shows the validity of the model. The influence of cutting parameters on cutting process is investigated by the simulation under different cutting depthes and rake angles. The results show that as the increase of rake angle, the segment degree, cutting force and cutting temperature decrease. But the segment degree, also the cutting force and cutting temperature increase with the increase of cutting depth. This study is useful for the selection of cutting parameters of hardened steel.

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