scholarly journals The effect of mesh parameters on computational cost and results in simulation of milling in Inconel 718

2021 ◽  
Vol 43 ◽  
pp. e52363
Author(s):  
Felipe dos Anjos Rodrigues Campos ◽  
Felipe Chagas Rodrigues de Souza ◽  
Pedro Henrique Pires França ◽  
Leonardo Rosa Ribeiro da Silva
Keyword(s):  
Experimental Data ◽  
Finite Element ◽  
Inconel 718 ◽  
Computational Cost ◽  
Cutting Speed ◽  
Cutting Conditions ◽  
Computational Time ◽  
Machining Processes ◽  
Element Mesh ◽  
Minimum Element

The Finite Element Method analysis of machining processes has become a ubiquitous feature to the area, however, there sometimes occur considerable deviations between experimental and simulated results due to the inherent complexity of the process. The basis for such may conceivably be related to imprecisions in the material and friction modelling, besides improper setup of mesh parameters. Elements should be small enough to allow for the proper representation of the chip formation, but taking into account that the computational time increases accordingly with mesh downsizing. Simulations of the milling process of Inconel 718 were conducted using the software Thirdwave AdvantEdge under different cutting conditions for three different meshes. Power and temperature output were compared to experimental results, most of which were measured via Hall-effect sensors and thermographic camera, respectively. The tool cutting edge radius was found to be an important factor and was estimated using Scanning Electron Microscope images. The influence of the finite element mesh size was higher for harsher cutting conditions, with effects felt on machining power only. In this case, finer mesh produced results that showed a higher agreement with experimental data, but at higher computational cost as shown by analysis of elapsed processing time. Although errors higher than 40% were observed, power and temperature trends from simulations were always in accordance with that found in experimental tests. Comparisons with experimental data from other studies showed the errors tend to grow for higher feed and cutting speed, which indicates the constitutive model of the material is more adequate for softer machining conditions. Simulation time seemed to be exponentially proportional to the inverse of minimum element size, and measured values might serve as a reference for other users.

scholarly journals Finite element simulation and regression modeling of machining attributes on turning AISI 304 stainless steel

2021 ◽  
Vol 8 ◽  
pp. 24
Author(s):  
A. Mathivanan ◽  
M.P. Sudeshkumar ◽  
R. Ramadoss ◽  
Chakaravarthy Ezilarasan ◽  
Ganesamoorthy Raju ◽  
...  
Keyword(s):  
Finite Element ◽  
Stainless Steel ◽  
Cutting Force ◽  
Cutting Speed ◽  
304 Stainless Steel ◽  
Computational Time ◽  
Depth Of Cut ◽  
Aisi 304 Stainless Steel ◽  
Machining Processes ◽  
Aisi 304

To-date, the usage of finite element analysis (FEA) in the area of machining operations has demonstrated to be efficient to investigate the machining processes. The simulated results have been used by tool makers and researchers to optimize the process parameters. As a 3D simulation normally would require more computational time, 2D simulations have been popular choices. In the present article, a Finite Element Model (FEM) using DEFORM 3D is presented, which was used to predict the cutting force, temperature at the insert edge, effective stress during turning of AISI 304 stainless steel. The simulated results were compared with the experimental results. The shear friction factor of 0.6 was found to be best, with strong agreement between the simulated and experimental values. As the cutting speed increased from 125 m/min to 200 m/min, a maximum value of 750 MPa stress as well as a temperature generation of 650 °C at the insert edge have been observed at rather higher feed rate and perhaps a mid level of depth of cut. Furthermore, the Response Surface Methodology (RSM) model is developed to predict the cutting force and temperature at the insert edge.

Data-driven seismic response prediction of structural components

2021 ◽  
pp. 875529302110533
Author(s):  
Huan Luo ◽  
Stephanie German Paal
Keyword(s):  
Experimental Data ◽  
Seismic Response ◽  
Computational Cost ◽  
Data Driven ◽  
Computational Time ◽  
Lateral Stiffness ◽  
Hysteretic Model ◽  
Structural Components ◽  
Rc Columns ◽  
Detailed Model

Lateral stiffness of structural components, such as reinforced concrete (RC) columns, plays an important role in resisting the lateral earthquake loads. The lateral stiffness relates the lateral force to the lateral deformation, having a critical effect on the accuracy of the lateral seismic response predictions. The classical methods (e.g. fiber beam–column model) to estimate the lateral stiffness require calculations from section, element, and structural levels, which is time-consuming. Moreover, the shear deformation and bond-slip effect may also need to be included to more accurately calculate the lateral stiffness, which further increases the modeling difficulties and the computational cost. To reduce the computational time and enhance the accuracy of the predictions, this article proposes a novel data-driven method to predict the laterally seismic response based on the estimated lateral stiffness. The proposed method integrates the machine learning (ML) approach with the hysteretic model, where ML is used to compute the parameters that govern the nonlinear properties of the lateral response of target structural components directly from a training set composed of experimental data (i.e. data-driven procedure) and the hysteretic model is used to directly output the lateral stiffness based on the computed parameters and then to perform the seismic analysis. We apply the proposed method to predict the lateral seismic response of various types of RC columns subjected to cyclic loading and ground motions. We present the detailed model formulation for the application, including the developments of a modified hysteretic model, a hybrid optimization algorithm, and two data-driven seismic response solvers. The results predicted by the proposed method are compared with those obtained by classical methods with the experimental data serving as the ground truth, showing that the proposed method significantly outperforms the classical methods in both generalized prediction capabilities and computational efficiency.

scholarly journals Sensitivity Analysis of Johnson-Cook Material Constants and Friction Coefficient Influence on Finite Element Simulation of Turning Inconel 718

Materials ◽  
2019 ◽  
Vol 12 (19) ◽  
pp. 3121 ◽  
Author(s):  
Xiaoli Qiu ◽  
Xianqiang Cheng ◽  
Penghao Dong ◽  
Huachen Peng ◽  
Yan Xing ◽  
...  
Keyword(s):  
Residual Stress ◽  
Sensitivity Analysis ◽  
Finite Element ◽  
Friction Coefficient ◽  
Constitutive Model ◽  
Cutting Force ◽  
Inconel 718 ◽  
Coulomb Friction ◽  
Cutting Conditions ◽  
Simulation Results

The Johnson-Cook (J-C) constitutive model, including five material constants (A, B, n, C, m), and the Coulomb friction coefficient (μ) are critical preprocessed data in machining simulations. Before they become reliable preprocessed data, investigating these parameters’ effect on simulation results benefits parameter-selecting. This paper aims to investigate the different influence of five settings of the J-C constitutive equation and Coulomb friction coefficient on the turning simulation results of Inconel 718 under low-high cutting conditions, including residual stress, chip morphology, cutting force and temperature. A three-dimensional (3-D) finite element model was built, meanwhile, the reliability of the model was verified by comparing the experiment with the simulation. Sensitivity analysis of J-C parameters and friction coefficient on simulation results at low-high cutting conditions was carried out by the hybrid orthogonal test. The results demonstrate that the simulation accuracy of Inconel 718 is more susceptible to strain hardening and thermal softening in the J-C constitutive model. The friction coefficient only has significant effects on axial and radial forces in the high cutting condition. The influences of the coefficient A, n, and m on the residual stress, chip thickness, cutting force and temperature are especially significant. As the cutting parameters increase, the effect of the three coefficients will change visibly. This paper provides direction for controlling simulation results through the adjustment of the J-C constitutive model of Inconel 718 and the friction coefficient.

Research on the importance of tool–workpiece separation in ultrasonic vibration–assisted milling

2016 ◽  
Vol 231 (4) ◽  
pp. 600-607 ◽  
Author(s):  
Mohammad Mahdi Abootorabi Zarchi ◽  
Mohammad Reza Razfar ◽  
Amir Abdullah
Keyword(s):  
Experimental Data ◽  
Ultrasonic Vibration ◽  
Vibration Amplitude ◽  
Cutting Speed ◽  
Machining Processes ◽  
Friction Behavior ◽  
Ultrasonic Assisted ◽  
The Times ◽  
Analytical Relations ◽  
First Time

In recent years, various reasons for improvement of performance and efficiency in ultrasonic vibration–assisted machining processes have been reported, which were mostly descriptive and without sufficient analytical and empirical proofs. Among the different machining processes, the least amount of experimental data and analytical relations exist about ultrasonic-assisted milling. In this article, for the first time in ultrasonic-assisted milling, we have determined the times of tool–workpiece engagement and their separation from each other in each vibration cycle and then investigated the influence of vibration amplitude and cutting speed on tool–workpiece effective engagement in ultrasonic-assisted milling. Contrary to ultrasonic-assisted turning, cutting time in each vibration cycle in ultrasonic-assisted milling is different from each other. With the aid of comprehensive experiments at tool–workpiece engagement angles smaller than 90°, we have proved that the main reason for average cutting force decrease in ultrasonic-assisted milling compared with conventional milling is the separation of tool and workpiece that occurs in a portion of each vibration cycle, and other factors such as change of friction behavior have less importance. At investigated tool–workpiece engagement angles, experimental and analytical results agree with each other.

Finite Element Method Simulation of Drilling Process on Metal-Matrix Composites

2011 ◽  
Vol 188 ◽  
pp. 372-375
Author(s):  
H.L. Zhang ◽  
Jin Chen
Keyword(s):  
Finite Element ◽  
Feed Rate ◽  
Shear Failure ◽  
Thrust Force ◽  
Equivalent Stress ◽  
Damage Model ◽  
Cutting Speed ◽  
Finite Element Method Simulation ◽  
Drilling Process ◽  
Machining Processes

Drilling is one of the complex machining processes, which has been widely applied in the manufacturing area. In this paper, a 3D coupled thermo-mechanical finite element model was used for simulating the thrust force, torque and von Mises equivalent stress at different cutting conditions. The J-C damage model (shear failure) was used in conjunction with the J-C plasticity model, as well as the continuous adaptive remeshing technical. The results show that the thrust force and torque increase with the increasing of the cutting speed and feed rate, and the influence of the feed rate is more obviously.

A Study of Cutting Forces in High-Speed Dry Milling of Inconel 718

2012 ◽  
Vol 500 ◽  
pp. 105-110 ◽  
Author(s):  
Huai Zhong Li ◽  
Jun Wang
Keyword(s):  
Cutting Forces ◽  
Inconel 718 ◽  
High Speed ◽  
Cutting Speed ◽  
High Yield ◽  
Dry Milling ◽  
Machining Processes ◽  
Dry Cutting ◽  
High Tendency ◽  
Coated Carbide

nconel 718 is one of the most commercially important superalloys but with very poor machinability. It has a very high yield stress and a high tendency to adhesion and work-hardening. A recent trend of improving the machining processes of difficult-to-cut materials is to move towards dry cutting operations. This paper presents an experimental study of the cutting forces in high speed dry milling of Inconel 718 using a milling cutter with coated carbide inserts. It is found that the peak cutting forces increase with an increase in chip load in a nonlinear way, but cutting speed does not show a significant influence on the cutting force for the range of cutting speeds tested in this study.

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%.

scholarly journals Influence of machining parameters on surface texture of Inconel 718 after grinding with multi-granular wheels

2019 ◽  
Vol 91 (3) ◽  
Author(s):  
Adrian Kopytowski ◽  
Rafał Świercz ◽  
Rafał Nowicki ◽  
Grigor Stambolov
Keyword(s):  
Surface Texture ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Processing Parameters ◽  
Feed Speed ◽  
Machining Parameters ◽  
Exploratory Research ◽  
Machining Processes ◽  
Advanced Machining ◽  
Machine Elements

Requirements currently imposed on machine elements are constantly growing. It requires to develop new, advanced machining processes. One of the commonly used finishing process is grinding. The article presents the results of the exploratory research in the process of surface grinding with abrasive multigrain wheels of samples made of Inconel 718. The influence of input parameters was investigated: cutting speed Vc, transverse feed speed Fp, longitudinal feed speed Fw, on roughness parameters (Sa) and the bearing capacity curve. Based on the conducted research, statistical models of the grinding process were elaborated, which allow to select the most favorable processing parameters depending on the required quality of the surface texture.

Cutting forces analysis of micro-milling process on Inconel 718 – a finite element approach

2020 ◽  
Vol 11 (02) ◽  
pp. 2050011
Author(s):  
Padmaja Tripathy ◽  
Kalipada Maity
Keyword(s):  
Finite Element ◽  
Cutting Forces ◽  
Inconel 718 ◽  
Cutting Speed ◽  
Fem Analysis ◽  
Milling Process ◽  
Machining Process ◽  
Micro Milling ◽  
Depth Of Cut ◽  
Machining Parameters

This paper presents a modeling and simulation of micro-milling process with finite element modeling (FEM) analysis to predict cutting forces. The micro-milling of Inconel 718 is conducted using high-speed steel (HSS) micro-end mill cutter of 1mm diameter. The machining parameters considered for simulation are feed rate, cutting speed and depth of cut which are varied at three levels. The FEM analysis of machining process is divided into three parts, i.e., pre-processer, simulation and post-processor. In pre-processor, the input data are provided for simulation. The machining process is further simulated with the pre-processor data. For data extraction and viewing the simulated results, post-processor is used. A set of experiments are conducted for validation of simulated process. The simulated and experimental results are compared and the results are found to be having a good agreement.

Improving finite element results in modeling heart valve mechanics

2018 ◽  
Vol 232 (7) ◽  
pp. 718-725 ◽  
Author(s):  
Emily Earl ◽  
Hadi Mohammadi
Keyword(s):  
Finite Element ◽  
Heart Valve ◽  
Numerical Technique ◽  
Strain Tensor ◽  
Computational Cost ◽  
Constitutive Models ◽  
Least Square ◽  
Computational Time ◽  
Finite Element Models ◽  
Fine Mesh

Finite element analysis is a well-established computational tool which can be used for the analysis of soft tissue mechanics. Due to the structural complexity of the leaflet tissue of the heart valve, the currently available finite element models do not adequately represent the leaflet tissue. A method of addressing this issue is to implement computationally expensive finite element models, characterized by precise constitutive models including high-order and high-density mesh techniques. In this study, we introduce a novel numerical technique that enhances the results obtained from coarse mesh finite element models to provide accuracy comparable to that of fine mesh finite element models while maintaining a relatively low computational cost. Introduced in this study is a method by which the computational expense required to solve linear and nonlinear constitutive models, commonly used in heart valve mechanics simulations, is reduced while continuing to account for large and infinitesimal deformations. This continuum model is developed based on the least square algorithm procedure coupled with the finite difference method adhering to the assumption that the components of the strain tensor are available at all nodes of the finite element mesh model. The suggested numerical technique is easy to implement, practically efficient, and requires less computational time compared to currently available commercial finite element packages such as ANSYS and/or ABAQUS.

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