The Study of Computer Simulation on Vibratory Metal Machining with Low Frequency

2007 ◽  
Vol 10-12 ◽  
pp. 286-290
Author(s):  
J.L. Song ◽  
Guang Jun Chen
Keyword(s):  
Computer Simulation ◽  
Formation Process ◽  
Chip Formation ◽  
Metal Cutting ◽  
Low Frequency ◽  
Metal Machining ◽  
Energy Consuming ◽  
Time And Energy ◽  
Insight Into ◽  
Good Agreement

Vibratory cutting is one of the newly developed machining techniques and theories in recent years. Insight into the machining mechanism and the chip formation process in metal vibratory cutting has yet to be carried out for this technique to be used widely and efficiently. But with conventional investigation, it is much difficult, and time and energy consuming to analyze and study such principles quantitatively. A system of the computer simulation has been established and based on FEM the chip formation process was emulated. The cutting forces and temperature distribution were imitated under condition of a variety of vibratory frequencies and turning engagements. ANSYS is utilized for the quantitative analysis. Contrast and comparison experiments between vibratory and the conventional metal machining are done, revealing a good agreement between the simulation and the experiment and the inborn nature and the principles of the vibratory metal cutting.

Dynamics of the processes in metal machining

1998 ◽  
Vol 2 ◽  
pp. 115-122
Author(s):  
Donatas Švitra ◽  
Jolanta Janutėnienė
Keyword(s):  
High Frequency ◽  
Machine Tools ◽  
Metal Cutting ◽  
Cutting Tool ◽  
Low Frequency ◽  
Metal Cutting Machine ◽  
Cutting Machine ◽  
Metal Machining

In the practice of processing of metals by cutting it is necessary to overcome the vibration of the cutting tool, the processed detail and units of the machine tool. These vibrations in many cases are an obstacle to increase the productivity and quality of treatment of details on metal-cutting machine tools. Vibration at cutting of metals is a very diverse phenomenon due to both it’s nature and the form of oscillatory motion. The most general classification of vibrations at cutting is a division them into forced vibration and autovibrations. The most difficult to remove and poorly investigated are the autovibrations, i.e. vibrations arising at the absence of external periodic forces. The autovibrations, stipulated by the process of cutting on metalcutting machine are of two types: the low-frequency autovibrations and high-frequency autovibrations. When the low-frequency autovibration there appear, the cutting process ought to be terminated and the cause of the vibrations eliminated. Otherwise, there is a danger of a break of both machine and tool. In the case of high-frequency vibration the machine operates apparently quiently, but the processed surface feature small-sized roughness. The frequency of autovibrations can reach 5000 Hz and more.

scholarly journals Simulation of plastic deformation and destruction in the process of chip formation

2018 ◽  
Vol 211 ◽  
pp. 17007
Author(s):  
Tanel Tärgla ◽  
Jüri Olt ◽  
Olga Liivapuu
Keyword(s):  
Plastic Deformation ◽  
Formation Process ◽  
Chip Formation ◽  
Rheological Model ◽  
Metal Cutting ◽  
Depth Of Cut ◽  
Key Factors ◽  
Local Zone ◽  
Complex Process ◽  
Relaxing Medium

Metal cutting is a complex process in which several mechanisms are at work simultaneously. The mathematical modelling allows carrying out research into the optimization of machining conditions. This work examines the simulation of chip formation during the process of cutting. The studies demonstrated that the chip formation process, taking into account the plastic deformation and destruction of metal in the local zone, is most appropriately represented by a rheological model in the form of a series connection of elasticductile- plastic relaxing medium of Ishlinskiy (reflecting the process of primary deformation of metal from the cut off layer) and the medium of Voigt with two elastic-dissipative elements (representing the process of deformation and frictions from the convergent shaving). The attained complex rheological model served as the basis for constructing a representative dynamic model for the chip formation process. The key factors that govern the chip formation have been taken into account, such as tool vibration frequency and amplitude, depth of cut, feed rate.

Study on the Modeling Method for Finite Element Analysis of Chip Formation Process

2010 ◽  
Vol 97-101 ◽  
pp. 2115-2118
Author(s):  
Li Jing Xie ◽  
Lin Li ◽  
Yue Ding ◽  
Xi Bin Wang
Keyword(s):  
Formation Process ◽  
Chip Formation ◽  
High Speed ◽  
Modeling Method ◽  
Arbitrary Lagrangian Eulerian ◽  
Element Analysis ◽  
Modeling Techniques ◽  
On Chip ◽  
Eulerian Methods ◽  
Good Agreement

FEM is a powerful tool for predicting cutting process variables, which are difficult to obtain with experimental methods. In this paper modeling techniques on chip formation by using the commercial FEM code ABAQUS are discussed. Because of the limitations of Lagrangian and Eulerian methods, a modeling method based on ALE (Arbitrary Lagrangian Eulerian) technology is proposed to simulate the chip formation process. It consists of three chip formation analysis steps, i.e. initial chip formation, chip growth and steady-state chip formation. With this modeling method, high speed turning process of stainless steel 2Cr13 is simulated. And the predicted variables are compared with experimental data. It has been found that the results are in good agreement with the experimental ones.

Numerical Analysis of Metal Cutting With Chamfered and Blunt Tools

2002 ◽  
Vol 124 (2) ◽  
pp. 178-188 ◽  
Author(s):  
M. R. Movahhedy, ◽  
Y. Altintas, ◽  
M. S. Gadala,
Keyword(s):  
Formation Process ◽  
Chip Formation ◽  
High Speed ◽  
Metal Cutting ◽  
Cutting Speed ◽  
Cutting Edge ◽  
Hard Materials ◽  
Ale Finite Element Method ◽  
Diffusion Wear ◽  
Process Simulations

In high speed machining of hard materials, tools with chamfered edge and materials resistant to diffusion wear are commonly used. In this paper, the influence of cutting edge geometry on the chip removal process is studied through numerical simulation of cutting with sharp, chamfered or blunt edges and with carbide and CBN tools. The analysis is based on the use of ALE finite element method for continuous chip formation process. Simulations include cutting with tools of different chamfer angles and cutting speeds. The study shows that a region of trapped material zone is formed under the chamfer and acts as the effective cutting edge of the tool, in accordance with experimental observations. While the chip formation process is not significantly affected by the presence of the chamfer, the cutting forces are increased. The effect of cutting speed on the process is also studied.

scholarly journals MESOMECHANICS OF THE CHIP FORMATION PROCESS DURING METAL CUTTING

2014 ◽  
Vol 1 (19) ◽  
pp. 52-59
Author(s):  
Vladimir A. Kim ◽  
◽  
Tatiana A. Otryaskina ◽  
Mikhail Y. Sarilov ◽  
◽  
...  
Keyword(s):  
Formation Process ◽  
Chip Formation ◽  
Metal Cutting

scholarly journals Dielectric Properties of Upside-Down SrTiO3/Li2MoO4 Composites Fabricated at Room Temperature

2021 ◽  
Vol 8 ◽  
Author(s):  
Nina Kuzmić ◽  
Srečo Davor Škapin ◽  
Mikko Nelo ◽  
Heli Jantunen ◽  
Matjaž Spreitzer
Keyword(s):  
Room Temperature ◽  
High Ratio ◽  
Drying Time ◽  
Promising Alternative ◽  
Pressing Time ◽  
Energy Consuming ◽  
Two Phases ◽  
Time And Energy ◽  
Lithium Molybdate ◽  
Insight Into

In this paper, ceramic upside-down lithium molybdate-strontium titanate (LMO-ST) composites fabricated at room temperature are described. Room temperature fabrication (RTF) is a promising alternative to the time- and energy-consuming high-temperature sintering of electroceramics, which involves mixing of the initial phases, molding with a steel dye, pressing, and drying, while in the last two phases the action of densification takes place. The LMO-ST composites are based on a high ratio of filler ST, coupled with the corresponding LMO binder. Part of the binder is admixed to the ceramic particles and additional part is added as a saturated aqueous solution, which crystallizes during pressing and drying, leading to its deposition on the surface of the filler particles. As a result, sufficient binding with 76–84% relative density was achieved. The deeper insight into the method was provided by various processing aspects and corresponding microstructural investigations. The particle size distribution, pressure, pressing time, ultrasonic treatment, drying time and processing conditions were optimized to obtain improved functional properties of the LMO-ST composites. The results of this study with relative permittivity in the range of 65–78 and dielectric loss tangent values of 0.002–0.05 can attract considerable attention for the use of LMO-ST composites in the industry of electroceramics.

Finite Element Analysis of the Influence of the Material Constitutive Law Formulation on the Chip Formation Process During a High Speed Metal Cutting

2012 ◽  
Author(s):  
Adinel Gavrus ◽  
Pascal Caestecker ◽  
Eric Ragneau
Keyword(s):  
Finite Element ◽  
Formation Process ◽  
Chip Formation ◽  
High Speed ◽  
Metal Cutting ◽  
Orthogonal Cutting ◽  
Constitutive Law ◽  
Cutting Process ◽  
Contact Friction ◽  
Numerical Predictions

During the last decades, the importance of machining in manufacturing industry has required rigorous scientific studies concerning the chip formation process in order to determine optimal speeds, feeds or other technological parameters. For all types of machining including turning, milling, grinding, honing or lapping, the phenomenon of chip formation is similar in terms of the local interaction between the tool and the work piece. Because of the intensive use of CNC machine tools producing parts at ever-faster rates, it has become important to provide analysis of high speed cutting where complex loading conditions occur during the fabrication process: high gradients of the thermo-mechanical variables, strong nonlinearities of the thermo-mechanical coupling, large plastic strains, extremely high strain rates compared to that of other forming processes, important influence of the contact friction and of the microstructure evolution. Today many scientific researches are focalized on finite element analyses of the chip formation and of its morphology evolution during a high speed metals cutting process. To improve the quality of the numerical predictions, a better description of the local shear band formation is needed, using adequate rheological models. On this point of view this paper deals with the influence of the rheological behavior formulation on the morphology and geometry of the chip formation during a finite element simulation of a high speed metal cutting process. Numerical simulations of a high speed orthogonal cutting of special steels are employed to analysis the sensitivity of the numerical results describing the local cutting area with respect to different rheological laws: Norton-Hoff or Cowper-Symonds model, Johnson-Cook one or Zerilli-Armstrong formulation. To obtain a better description of the local material loadings and to take into account the important gradient of the strain rate, plastic strain and temperature values, a more adequate constitutive model is proposed by the author.

Prediction and computer simulation of dynamic thrust and torque in vibration drilling

1998 ◽  
Vol 212 (6) ◽  
pp. 489-497 ◽  
Author(s):  
L-P Wang ◽  
L-J Wang ◽  
Y-H He ◽  
Z-J Yang
Keyword(s):  
Computer Simulation ◽  
Simulation Study ◽  
Deformation Process ◽  
Low Frequency ◽  
Frequency Range ◽  
Vibration Cutting ◽  
Theoretical Predictions ◽  
Vibration Drilling ◽  
Thrust And Torque ◽  
Good Agreement

A predictive model for dynamic thrust and torque in vibration drilling is presented. The model is based on the mechanics of vibration cutting analysis, assuming that the deformation process at the lips and chisel edge is treated as a number of vibration cutting elements, each with different dynamic characteristics. The result of a simulation study conducted for a low frequency range has shown a very good agreement between the theoretical predictions and the experimental evidence.

Decelerative Cutting of 6061-T9 Aluminum, 65-35 Brass, and TPE Copper With Constant Impact Energy

1973 ◽  
Vol 95 (3) ◽  
pp. 904-912 ◽  
Author(s):  
M. H. Pleck ◽  
B. F. Von Turkovich
Keyword(s):  
Steady State ◽  
Formation Process ◽  
Chip Formation ◽  
Metal Cutting ◽  
Rake Angle ◽  
Velocity Dependence ◽  
State Tests ◽  
Dynamic Velocity ◽  
Cutting Velocity ◽  
Energy And Momentum

The chip formation process during metal cutting in which the cutting velocity is permitted to decrease freely is examined from an experimental standpoint. Metal cutting data are obtained from a specially constructed decelerative cutting apparatus for 6061-T9 aluminum, 65-35 brass, and TPE copper under the test conditions of constant energy input and variable initial momentum, velocity, and rake angle. The overall mechanics of chip formation are found to be essentially identical to that for the steady state, including a similarity of the dynamic velocity dependence of cutting forces to their velocity dependence in steady state tests. A complex velocity dependence is noted for 6061-T9 Aluminum. Further evidence of the constancy of the dynamic shear stress is presented. Kinetic energy and momentum are found to have no significant effects upon the chip formation process.

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