Modeling and Simulation of Induction Heating with Magnetic Flux Concentrator

2012 ◽  
Vol 268-270 ◽  
pp. 983-991 ◽  
Author(s):  
Feng Li ◽  
Xue Kun Li ◽  
Tian Xing Zhu ◽  
Qian Zhe Zhao ◽  
Yi Ming Kevin Rong
Keyword(s):  
Finite Element ◽  
Magnetic Flux ◽  
Modeling And Simulation ◽  
Electric Fields ◽  
Induction Heating ◽  
Element Model ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Flux Concentrator

Induction heating possesses wide application in surface hardening for steels. In recent years, the emergence of metal powder bonded magnetic flux concentrator (MPB-MFC) enables induction heating better capability, efficiency, and controllability, therefore the analytical understanding through modeling and simulation becomes necessary for process design and optimization. In this paper, the mechanism of the energy transformation in induction heating with magnetic flux concentrator is carried out. The MPB-MFC assisted induction heating for AISI 1045 steel is studied by comparing the finite element simulation with experimental results. The finite element model solves the coupled electro-magnetic-thermal computation problem, which also involves the consideration of the non-linear material magnetic properties in the process. To verify the simulation, middle-frequency induction heating experiments are conducted to compare with the simulated results. The comparison proves the efficacy of the FEM model, and discloses the inner-correlation of the thermal-magnetic-electric fields in the process.

Analysis of the Heat Affected Zone and Surface Roughness during Laser Micromachining of Metals

2019 ◽  
Vol 827 ◽  
pp. 122-127
Author(s):  
Evaggelos Kaselouris ◽  
A. Skoulakis ◽  
Yannis Orphanos ◽  
K. Kosma ◽  
T. Papadoulis ◽  
...  
Keyword(s):  
Surface Roughness ◽  
Finite Element ◽  
Heat Affected Zone ◽  
Material Model ◽  
Element Model ◽  
H13 Steel ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Aisi H13 ◽  
1045 Steel

The current research focuses on the characterization of the produced heat affected zone when laser heats AISI H13 steel, AISI 1045 steel and Ti6Al4V alloy workpieces via finite element simulations and experimental investigation. The surface roughness designedly varies on the surface of the samples and its influence on the absorption of laser light is investigated. Experiments are conducted at 1-4 W laser power and for two scanning speeds of 2 and 100 mm/min. A 3D transient thermo-structural finite element model for a moving Gaussian laser heat source is developed to simulate the micromachining process and predict the depth and width of the heat affected zone. The Johnson-Cook material model that takes into account the effect of plastic strain, strain rate and temperature, along with a fracture model, is adapted to the simulations. A good agreement between the experimental data and the simulation results is found. The depth and width of the heat affected zone strongly depend on the laser parameters and material properties of the irradiated samples. This study constitutes the basis to the optimization and improvement of the laser assisted micromachining process parameters and provides key insights on the roughness-absorptivity relation for the three metallic materials.

A Parametric Study of the Modeling of Orthogonal Machining Using the Smoothed Particle Hydrodynamics Method

2015 ◽  
Author(s):  
Chinmay S. Avachat ◽  
Harish P. Cherukuri
Keyword(s):  
Finite Element ◽  
Smoothed Particle Hydrodynamics ◽  
Chip Morphology ◽  
Machining Processes ◽  
Orthogonal Machining ◽  
Particle Hydrodynamics ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Smoothed Particle ◽  
1045 Steel

Modeling machining processes with conventional finite element methods (FEM) is challenging due to the severe deformations that occur during machining, complex frictional conditions that exist between the cutting tool and the workpiece, and the possibility of self contact due to chip curling. Recently, the Smoothed Particle Hydrodynamics (SPH) method has emerged as a potential alternative for modeling machining processes due to its ability to handle severe deformations while avoiding mass and energy losses encountered by traditional FEM. The method has been implemented in several commercial finite element packages such as ABAQUS and LS-DYNA for solving problems involving localized severe deformations. Numerous control parameters are present in a typical SPH formulation. The purpose of this work is to evaluate the effect of the three most important parameters, namely, the smoothing length, particle density, and the type of SPH formulation. The effects of these parameters on the chip morphology and stress distribution in the context of orthogonal machining of AISI 1045 steel are investigated. The LS-DYNA finite element package along with Johnson-Cook material model is used for this purpose. Results from the parametric study are presented and compared with the previously reported results in the literature. In addition, the sensitivity of chip morphology and stresses to Johnson-Cook parameters for AISI 1045 steel is also investigated by considering five different sets of values reported in the literature for this steel.

scholarly journals Finite Element Modeling and Validation of Chip Segmentation in Machining of AISI 1045 Steel

Procedia CIRP ◽  
2017 ◽  
Vol 58 ◽  
pp. 499-504 ◽  
Author(s):  
Ashwin Devotta ◽  
Tomas Beno ◽  
Raveendra Siriki ◽  
Ronnie Löf ◽  
Mahdi Eynian
Keyword(s):  
Finite Element ◽  
Finite Element Modeling ◽  
Element Modeling ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

scholarly journals FINITE ELEMENT MODELING OF TEMPERATURE FIELDS ON THE CUTTING EDGE IN THE DRY HIGH-SPEED TURNING OF AISI 1045 STEEL

2020 ◽  
Vol 18 (2) ◽  
pp. 205
Author(s):  
Roberto Pérez ◽  
Luis Hernández ◽  
Ana Quesada ◽  
Julio Pino ◽  
Enrique Zayas
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
High Speed ◽  
Cutting Tools ◽  
Temperature Fields ◽  
High Speed Turning ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel ◽  
Conventional Machining

High-speed turning is an advanced and emerging machining technique that, in contrast to the conventional machining, allows the manufacture of the workpiece with high accuracy, efficiency and quality, with lower production costs and with a considerable reduction in the machining times. The cutting tools used for the conventional machining cannot be employed for high-speed machining due to a high temperature induced in machining and a lower tool life. Therefore, it is necessary to study the influence of high cutting speeds on the temperature distribution in different typologies of cutting tools, with the aim of evaluating their behavior. In this paper, a finite element method modeling approach with arbitrary Lagrangian-Eulerian fully coupled thermal-stress analysis is employed. The research presents the results of different cutting tools (two coated carbide tools and uncoated cermet) effects on average surface temperature fields on the cutting edge in the dry high-speed turning of AISI 1045 steel. The numerical experiments were designed based on different cutting tools like input parameters and different temperature field zones like dependent variables in the dry high-speed turning of AISI 1045 steel. The results indicate that the dry high-speed turning of AISI 1045 steel does not influence significantly the temperature field zones when P10, P15 or P25 inserts are used. Therefore, the use of a dry high-speed turning method, which reduces the amount of lubricant and increases productivity, may represent an alternative to turning to the extent here described.

Effect of longitudinally intermittent movement of cutting tool in drilling of AISI 1045 steel: A three-dimensional numerical simulation

2018 ◽  
Vol 233 (12) ◽  
pp. 4081-4090 ◽  
Author(s):  
Mohammad Lotfi ◽  
Saeid Amini
Keyword(s):  
Cutting Tool ◽  
Thrust Force ◽  
Three Dimensional ◽  
Element Model ◽  
Machining Process ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
Lower Temperature ◽  
Three Dimensional Finite Element ◽  
1045 Steel

Applying ultrasonic vibrations in machining process is an effective method to improve desired machinability factors. In this study, a three-dimensional finite element model is developed to evaluate effect of added vibratory movement of cutting tool on output parameters in conventional drilling of AISI 1045 steel. Heat generation on drill faces, strain, and damage of deformed chip in addition to thrust force are taken into account to be analyzed. Besides, a dynamometer and a vision measuring microscope are used to investigate generated thrust force and built-up edge during conventional and ultrasonic-assisted drilling. As a result, it is shown that vibratory movement of drill bit results in lower temperature to be generated on tool faces resulting in almost elimination of built-up edge. Moreover, higher damage value resulted by additional chip bending is observed when ultrasonic vibration is added to the operation.

Finite Element Simulation and Experimental Analysis of Cutting Forces in Orthogonal Turning in AISI-1045 Steel

2019 ◽  
Vol 23 (1) ◽  
Author(s):  
Marco Antonio Prieto Juárez ◽  
Eduardo Aguilera Gómez ◽  
Héctor Plascencia Mora ◽  
Elías Ledesma Orozco ◽  
Juan Francisco Reveles Arredondo ◽  
...  
Keyword(s):  
Finite Element ◽  
Finite Element Simulation ◽  
Experimental Analysis ◽  
Cutting Forces ◽  
Element Simulation ◽  
Orthogonal Turning ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel

Influence of magnetic flux concentrator on the induction heating process in crystal growth systems-geometry investigation

CrystEngComm ◽  
2018 ◽  
Vol 20 (48) ◽  
pp. 7857-7865 ◽  
Author(s):  
Hamed Heidari ◽  
Mohammad Hossein Tavakoli ◽  
Sayed Omid Sobhani ◽  
Mohtaram Honarmandnia
Keyword(s):  
Finite Element Method ◽  
Finite Element ◽  
Crystal Growth ◽  
Magnetic Flux ◽  
Induction Heating ◽  
Heating Process ◽  
Geometry Effect ◽  
Czochralski Crystal Growth ◽  
Growth System ◽  
Flux Concentrator

In this paper, a magnetic flux concentrator (MFC) is reported, and its geometry effect on the induction heating process has been calculated in a Czochralski crystal growth system using the 2D finite element method.

scholarly journals The 2D Finite Element Microstructure Evaluation of V-Shaped Arc Welding of AISI 1045 Steel

Metals ◽  
2017 ◽  
Vol 7 (2) ◽  
pp. 41
Author(s):  
Omer Eyercioglu ◽  
Ahmed Anwar ◽  
Kursat Gov ◽  
Necip Yilmaz
Keyword(s):  
Finite Element ◽  
Arc Welding ◽  
Microstructure Evaluation ◽  
Aisi 1045 Steel ◽  
Aisi 1045 ◽  
1045 Steel
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